Topic: CB750 K0 Switches/Instrument Harness Routing

[major domo]

Need to know how the wiring harnesses for the instruments and handlebar harnesses are routed: Do these all route thru the headlamp bucket, or do some of these just get tucked behind the bucket after connecting with the main loom? Thanks in advance!

[Sandy]

major domo:

On my 1969, both the left- and right-switch wires are threaded through the handlebars and into the headlight bucket.  It can get a little tight inside the headlight bucket, but I have done this several times and both sets of wires fit just fine.  If your wires are threaded through the handlebars, tie a string or something small to the wires coming out of the headlight bucket, and very carefully pull the wires through the handlebar.  This will make it a lot easier to pull the new wires through the handlebars.  Good luck with the routing and let us know how this task eventuated.

[b52bombardier1]

I used a length of electric fence wire to help fish my recently replaced right hand switch assembly through the handlebars.  It's a "pull and push" technique for getting things through the handlebars. Just don't pull so hard as to damage the individual wires. Then grab the individual wires with needle nose pliers as they appear at the hole at the bottom of the bars.

  I had to do this once before some years ago on a set of bars that were very rusty on the inside.  It took liberal amounts of KY Jelly to get that set of wires through but it was not needed last week on my CB500.

Rick

[Sandy]

I will also add that it will be much easier to thread these wires if you remove the handlebars .  This is not necessary, but it makes this task much easier .

[Don R]

 It seems like a lot of wires until you do a late super sport, then it's not so much. I fold the wires back at different lengths to form a point and tape over them including the pull wire. Then a little lube, pushing and pulling and away you go.  Aftermarket bars may be rough or sharp at the holes, I file the sharp edges to make them smooth and allow the wire bundle to slide easily.
 Patience is a virtue.