Switching handlebars

So I bought some superbike bars for my 78 kz650 sr D. I realize that I will have to drill holes for the cables. BUT how the fuck do I get the cables out of the existing bars? They are soldered into the light switches and shit. Do I have to un-solder them?? Please help thanks


Mike;

Don't drill them. That was done only on a few years of models. Run the cables on the outside like Kawasaki started to do in 1979.

otakar wrote:

Don't drill them. That was done only on a few years of models. Run the cables on the outside like Kawasaki started to do in 1979.

Thanks for the info, but that's not the info im looking for. I can't figure out how to get these wires out of the bars.

Does anyone know?

Trace the wires to the end opposite the switches. There are bullet connectors that you can seperate. Then you can pull the wires through the bars toward the switch end. Be careful as they will be tight, and it is easy to damage wires by dragging them across the jagged edge of that hole in the bars. After you get them pulled, then you will agree with otakars advice about running them outside the new bars. Good luck.

First grips come off. Sometimes it's easiest to just cut them off and replace 'em. Next disconnect your control cables- i.e. throttle and clutch and choke? Now, I hope you like spaghetti cuz your about to be elbows deep in it! If all your handlebar switch gear is working alright, in good condition, and you don't want to mess with it you have to disconnect all those bullet connectors where they attach to the harness. Generally, this is inside the headlight bucket, I don't know about 78 kz650 specifically. That's a healthy amount of spaghetti huh:ohmy: Be sure to mark or be able to identify exactly how to replace these wires otherwise it's gonna be a long, frustrating time before you ride that bike again. Got access to your bike's wiring diagram? Good. Next, Unbolt your original bars and your left with the unclamped switch pods hangin' off the ends and a big mess of colored wires hangin out of the middle. Now you are gonna try as gently as possible, to pull those wires out the holes in the bars. Work slowly. Try not to damage the connections in the switch pods. WD40 sprayed into the inside of the bars liberally may help if they stick. Hope it's not rusty inside your bars cuz then the wiring tends to bond itself to the inside of the bars. Whatever you do, don't use a propane torch to heat the bars in an attempt to break this rust bond. Sliding out a gelatinous mass of molten copper and rubber is no fun.

The simplest way to do it is to clip off the connectors and replace them once the harness is pulled out.

I think these bullet connectors are under my gas tank and I have no idea how to take that off.

The switches have holes in them for the wires, but they are set up for the holes on the bars. I don't think I can run the wires outside of the bar without drilling holes in my switches for the wires to come out of.

Does anyone know how to take the gas tank off of a 78 KZ650 Sr D?

Thanks for all the help

As far as the switches...yeah thats basically what you have to do. The best way to do it is to grind out some clearance for the wiring on the concave surface of the switch pod where it clamps to the handle bars. I don't know what tools you have access to... die grinder with a small burr works real quick, dremel tool could probably do it good too. I could even see myself drilling a 3/8" or so hole close to the edge and hacksawing it out. Removing gas tank? Once again I don't know the specifics of the KZ650 but Ive never seen a bike that wasn't similar to something like this... open the seat, there should be some sort of flexible rubber hold down for the back of the seat under there, unhook the hold down and lift the back of the tank slightly, make sure all your fuel/vacuum lines are unhooked, makes sure you know what ones go where for when you put it back, then simply pull the tank towards the back of the bike. I can post photos of my KZ1000 project if you can't understand this description but can anybody find some for a 650?

the rubber bandy thing that holds tail of tank down

lift the tank up and pull back