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Club bar swap wiring help
- Brian kz650
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- testarossa
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Be careful pulling the wires through the bars. I managed to pop three of the connections soldered in my switch pods when I pulled mine. As to trying to pull the wires back through the bars all I can say is good luck. I'm guessing that the factory pulled the wires first and then crimped on all the connectors. You'll find out what I mean when you go to pull the wires. I wasn't about to try to get them back through there. Unless the new bars have a larger diameter inside than the stock bars.
1978 KZ1000 A2 Click--->Build Thread
2004 ZX-10R
2007 Harley Sportster 1200
2020 Harley Street Glide Special
Angola, IN
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- Brian kz650
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- testarossa
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Good luck.
PS I suggest that you de-burr the edges of the holes in your stock bars before you attempt to pull the wires. The holes are stamped in and have jagged edges perfect for cutting wires and snagging connectors. Possibly shoot some form of lubricant in the bar to assist in sliding the wires through.
1978 KZ1000 A2 Click--->Build Thread
2004 ZX-10R
2007 Harley Sportster 1200
2020 Harley Street Glide Special
Angola, IN
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- 650ed
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1977 KZ650-C1 Original Owner - Stock (with additional invisible FIAMM horn)
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- MFolks
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Use the highest speed for better control, and have both hands on the tool if possible. For the best result, put the handlebars in a vice, to prevent scarring the chrome/paint, wrap the bars with several layers of rags and tape.
If the burrs are not removed, they will strip the insulation from your wires in a second! Noting quire like troubleshooting a dead short inside new handlebars.
1982 GPZ1100 B2
General Dynamics/Convair 1983-1993
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- Brian kz650
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- 650ed
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Thanks for all the replies, I will be starting this tomorrow,hopefully finishing tomorrow as well, next will be chopping the back of the frame and putting on a cafe seat,but one thing at a time, thanks again,Brian
You're going to hacksaw a '77 KZ650? Egads! Oh well, another one bites the dust. Ed
1977 KZ650-C1 Original Owner - Stock (with additional invisible FIAMM horn)
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- Brian kz650
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- 650ed
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I love the cafe, and flat tracker look since I was a kid and thats why I got this bike.
Me too, but I've never seen a cafe or flat tracker that looks good with 4 cylinders. To me, the engine is simply too wide for that style to look proportioned right. I'm more of an old school guy who considers flat trackers and cafes to be twins or one lungers. Ed
1977 KZ650-C1 Original Owner - Stock (with additional invisible FIAMM horn)
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- rstnick
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I've got the wires outside the bars on my bike. Have had them that way with a few different style of bars. Does tidy them up inside though.
Rob
CANADA
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1978 KZ650 C2, 130K kms, Delkevic ex, EI, CVK32, PMC easy clutch, ATK fork brace, steering damper, braced swingarm, 18" Z1R front wheel.
2000 ZRX1100
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- Brian kz650
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