Stock bars to new clubmans

Hi guys,
Just bought some new clubmans for my KZ650B that I'm turning into a cafe .Can anyone tell me how to change them over? Currently my wires run through my stock bars...am I in for big trouble or should I bring the bike in to get it professionally done?:whistle:

Welcome to KZR.

I'm putting Clubman Bars on my 650 as well this Winter. Now I've had non stock bars on for years, so I had modified my handlebar switches to allow the wires to run outside the bars. I just filed an openning to allow the wire to run out of. Some will drill the new bars and run the wires through. Some bars will come with holes already in them, but they may not line up for your purpose.

Post edited by: rstnick, at: 2006/01/18 10:12

you should be able to pull the wires thru the bars.

you will need to gain access to the main junction at the front of the harness. the wires from the bars should join up to the harness there with bullet connectors.

the wires should be color coded, do one side at a time. remove all the bullets from the junction for one side, work the wires out, then run them back to the junction and plug them back in.

lather, rinse, repeat for the other side.

i've not done this in probably 13 years, so if i forgot something, someone please chime in.

--r

Some clubman bars arent hollow where the bars are welded together. Blow through the end to see if yours are. Some have sharp edges where they are welded together. Figure out where the wires will be and put extra electrical tape where the sharp edges will be.
If you put a string in the end (where the wires enter) and blow it through with air pressure it should come out of the center (where the wires exit). This makes it easier to pull your wires through the bars. Push the wires in while pulling on the string. It will take some time but the clean look is worth the effort.
Fish

I had the same problem when I did mine, when I got to looking at old-school cafe bike pictures almost all of them left the wires out, I just got some of that braided stainless wire loom off line and ran my wires through it. Gives it a custom look, and I spent way less time, you will have all od the wire disconnected anyway. Depends on the look you want I guess. Just remember if you have wiring trouble or need to replace a switch in the future maybe leaving the wires out will benefit you. Here is a link.

cgi.ebay.com/ebaymotors/BRAIDED-CABLE-HO...QQrdZ1QQcmdZViewItem

Post edited by: Wildog, at: 2006/01/19 11:53

You will have brown braided wires unless you spring for the stainless.

how about eliminating the handlebar mounted electrical stuff and mounting it somewhere else?i dont have turnsignals or horn or flashers or any of that kind of stuff on my bikes so it really simplifies things for me!goodluck,happy wrenching! :whistle:

Post edited by: wireman, at: 2006/01/19 22:08

Just did this today on my wifes 650. Solomrus is right on the money.

Just did this today on my wifes 650. Solomrus is right on the money.

wireman wrote:

i dont have turnsignals or horn or flashers or any of that kind of stuff on my bikes so it really simplifies things for me!

I've found that stuff to come in really handy at times! You do take your bikes on public roads... right?

arm straight out for left,out and up for right turn piece of cake!right out of the drivers license manual,dont have mirrors or turn signal brackets on frame or reflectors found i tend to concentrate more on whats going on around me more rather than hoping that other people see a turn signal flashing.goodluck,happy wrenching!:whistle: