Topic: easiest way to swap out bars?

[wilson889]

Hey all, this is probably the dullest question but what is the easiest way swapping out stock handlebars for clubmans as far as wiring goes? I was going to make an attempt yesterday but then i just saw the mess of wires behind headlight and that was enough to deter me from doing so. So basically what shall i do to get the wiring out of the stock bars? lol
Sorry for the question but someone's got to ask.. and it'll be interesting to see how others did so..

[mystic_1]

There's no shortcuts here.  Don't let the wiring intimidate you, it's not as hard as it looks.

I recommend you label each connection as you unplug it.  Label both sides of the connection.  You can buy numbered wire labels at the hardware store, or just use masking tape.

Follow the wiring that comes out of the bars, into the headlight shell.  There's only really a hand full of wires from each side.  Label and disconnect those and then pull them out of the headlight shell.  No need to crack open the brake lines, unless you're changing them for shorter ones, otherwise just unbolt the master cylinder and set it aside.  Be careful, keep it more-or-less upright, brake fluid loves to eat paint.  You'll want to fully remove the throttle cables as they'll need to be re-routed to avoid sharp kinks or bends (you may want to get shorter ones for clubmans).

As you're disconnecting the wiring, examine the condition of the bullet connectors.  If they're tarnished or corroded, clean them up nice and bright before putting things back together.

You'll find that the hardest part of the whole thing is probably going to be pulling the wiring into the new handlebars.  Some people choose to notch the switch housings and run the wiring externally, but I prefer to run the wiring internally as it looks much cleaner that way.

mystic_1

[Johnie]

Mystic hit it on the head...there is no easy way. Effort and time is involved for sure. I hope you are not colored blind. And I think the hardest part is the pulling of the wires. Just take your time. If you get frustrated leave and come back another day. I use some silicone spray to help lube the cables when removing and installing. They will not come out with one quick pull. You have to work them a little bit at a time (push a little / pull a little / push a little / etc.) I use electrical tape to get the bullet ends together. Then I tie a small tough string to that end and thread that string through the bars. That way I can push and pull a little at a time. Good luck with it.

[mystic_1]

I hope you are not colored blind.

Funny thing is, I AM

That's another reason I tag everything carefully.  That's also why wiring was one of the first things my wife learned how to do on a bike

"Honey, what color is this wire?"

It's not so bad really, I'm not fully colorblind just "color deficient" so I can tell a yellow wire from a red wire from a black wire from a blue wire, but some of the stripes give me trouble and I have to be careful.  It just takes me a little longer because I double and triple check things.  I've never melted a harness so I think I'm doing ok

I hear that pulling wire through clubmans can be a challenge.  I run 10 inch apes though

mystic_1

[wilson889]

Ok Thanks for all the info, oh and another thing, does any clubmans out there have the precut slots to feed the wires through? Mine do not, any certain way to cut it?

[mystic_1]

Scroll to the top of this page.  Click "Search" in the blue menu.  At the Search Parameters screen, type "drilling handlebars" without the quotes, then click search.  There are many threads on this topic.

Don't use the search box on the right side up there, that just searches the current thread, or the current forum section if you're looking at an index page at the time.

mystic_1