bar end turn signals ?

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21 Apr 2014 11:40 #629864 by pete greek1
bar end turn signals ? was created by pete greek1
I'm going to put superbike bars on my 76 900 Ltd & was thinking of bar end signals, but I'm worried about drilling 2 holes in the bars for the wires, has anyone done this ???

1980 LTD 1000..,1976 LTD 900, have the 1000&900 now. the rest are previous= 1978 KZ 650 B.., 1980 Yamaha XT 500..,1978 Yamaha DT 400.., 1977 Yamaha yz 80..,Honda trail ct 70.., Honda QA 50...5-1/2 hp brigs & straton CAT chopper mini bike...3-1/2 hp mini bike (WHEN GAS WAS ABOUT 45 CENTS A GALLON)!!!!

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21 Apr 2014 12:49 #629868 by MFolks
Replied by MFolks on topic bar end turn signals ?
I'd ask around at the local machine shops, as milling the holes will be more accurate than drilling them. and here's information about pulling the wires through the new handlebars:

Pulling Wire Bundles Inside Handlebars

Before running any wiring inside the bars, take time to see if any sharp "Burrs" are there, otherwise they will quickly strip any insulation away from the wire's conductors, resulting in an electrical short.

A Dremel tool with a small stone grinding bit will smooth most burrs away. If a Dremel is not available, a small round rat tail file works just as good.

Any electrical wire splices, should be “Staggered” to avoid a lump, so the bundle will pull smoothly through the handlebar(s).

When preparing to pull the wire bundle through the bars, carefully taper the bundles end with masking tape as this makes for a better pulling situation.

I use aircraft 0.032" diameter safety wire secured to the wire bundle as a pulling medium, Nylon string or small diameter cord will work for this too.

Silicone spray or electricians pulling lubricant should be applied to the end of the wires to ease the operation. It's best to have a helper while doing this to avoid problems of possible pinched or damaged wires. Have your helper apply a steady pulling effort while you carefully feed the wire bundle into the handlebars.

After the job of pulling is done, get a multimeter, set it on the lowest ohm setting, open up the switch housings to access the wire ends and then see if a wire of two has shorted out.

Put one probe on the handlebar and the other on any soldered wire ends on the switches and see if the meter indicates continuity by either making a buzz(some meters have built in buzzers) or a display on the meter face.

An analog meter(the type with the needle indicator) will act similar (except no buzzer) by showing usually a full deflection(needle movement)if there is a short by again, checking with the lowest setting on the ohm scale of the meter.

Finding a short now is a whole lot better than when it's wired up & blowing fuses or possible stranding you on the road.....

1982 GPZ1100 B2
General Dynamics/Convair 1983-1993
GLCM BGM-109 Tomahawk, AGM-129A Advanced Cruise Missile (ACM)
The following user(s) said Thank You: pete greek1

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22 Apr 2014 07:45 #629953 by pete greek1
Replied by pete greek1 on topic bar end turn signals ?
Thanks MFolks, I have a machine shop in the area...I"ll start there !!

1980 LTD 1000..,1976 LTD 900, have the 1000&900 now. the rest are previous= 1978 KZ 650 B.., 1980 Yamaha XT 500..,1978 Yamaha DT 400.., 1977 Yamaha yz 80..,Honda trail ct 70.., Honda QA 50...5-1/2 hp brigs & straton CAT chopper mini bike...3-1/2 hp mini bike (WHEN GAS WAS ABOUT 45 CENTS A GALLON)!!!!

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22 Apr 2014 08:39 #629954 by kaw-a-holic
Replied by kaw-a-holic on topic bar end turn signals ?
I've done it without issues. Some guys just zip tie the wires on the outside. I personally like the clean look. A drill press makes the job easy. I am switching out the stock controls for a unit from Dennis Kirk that has everything on one control. It includes a brights indicator, turn indicator and an automatic turn indicator cancellation. Pretty sweet its $87

Jon
1977 KZ1000a1
Mesa, AZ
Phoenix Fighter Project

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22 Apr 2014 09:07 #629958 by pete greek1
Replied by pete greek1 on topic bar end turn signals ?
kaw-a-holic, sounds nifty, but I just bought a set of left & right controls from Z1 e, I was more concerned about the integrity of the after market bars with holes drilled in them, but I guess they'll be fine B) !!

1980 LTD 1000..,1976 LTD 900, have the 1000&900 now. the rest are previous= 1978 KZ 650 B.., 1980 Yamaha XT 500..,1978 Yamaha DT 400.., 1977 Yamaha yz 80..,Honda trail ct 70.., Honda QA 50...5-1/2 hp brigs & straton CAT chopper mini bike...3-1/2 hp mini bike (WHEN GAS WAS ABOUT 45 CENTS A GALLON)!!!!

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22 Apr 2014 11:59 - 22 Apr 2014 12:00 #629975 by baldy110
Replied by baldy110 on topic bar end turn signals ?
No worries about drilling the two small holes for the wires, it will not effect the integrity of the bars. I do that all the time, in fact when I crashed my bike in 2011 I had the bar end turn signals and drilled the holes for the wires. It took a very bad crash to get the bars to bend, 75 mph down on pavement. The left side of the bars bent down but did not crack at the holes I had drilled.
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Last edit: 22 Apr 2014 12:00 by baldy110.

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22 Apr 2014 12:56 #629981 by pete greek1
Replied by pete greek1 on topic bar end turn signals ?
F..k da bike....Lucky you are in One piece !!!

1980 LTD 1000..,1976 LTD 900, have the 1000&900 now. the rest are previous= 1978 KZ 650 B.., 1980 Yamaha XT 500..,1978 Yamaha DT 400.., 1977 Yamaha yz 80..,Honda trail ct 70.., Honda QA 50...5-1/2 hp brigs & straton CAT chopper mini bike...3-1/2 hp mini bike (WHEN GAS WAS ABOUT 45 CENTS A GALLON)!!!!

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