Tips for Internally wiring handle bars.

I was having a hell of a time feeding my shrink wrapped wires down the clubman bars I got. I overcame the difficulty with some simple tools. A piece of extension cord or any strong flexible wire, some super glue, a peice of sting and a split shot fishing lure.

First attach the split shot to the string, jiggle it down from the controls hole to the exit hole. Now, super glue the sting to the piece of cord and glue the other end of the piece of cord to the wires coming from the controls, cut off the male bullet connections first or you will never make the turn, (do not remove the shink wrap it will protect the wires and make life easier, trust me). Now, greese up the shrink wrap with lithium greese and begin to pull it through via the wire you already threaded through. Next you use a wooden down to push the wire down the handle bars. Just insert it in the bar end and jam the wire down in the direction you want it to go while your partner pulls the cord to pull it along. I threaded my handle bars in this fashion in a matter of minutes, and the shrink wrap takes all the punishment so no shorted or stripped wires. The dowl pushes it around that corner and allows you to feed the wire into the bars much more easily. Plus don't forget a shitload of greese on the srink wrap to help it like easily. It looks so clean and nice, definately woth the extra effort. Your making a bad ass bike, don't be a lazy pussy and skimp on the internal wiring for your bars. Hope this helps somebody!!! It definately takes some of the pain out of doing the job.

Good Post

you can also use a shop vac and string...
~ tie string to the wires tape it good...
~ slide string in the bars
~ tape off all openings except the exit hole.
~ place vac on the hole you want them to exit
~ the vac pull the string to the hole
~ grab it and pull the wires through
Just another method for those wondering

Pulling a whole pile of wiring through clubman bars is no easy task and tape would not work in my case. It took gorrilla glue and 2 people, one pulling and one feeding to make it go. The wooden dowel makes feeding it in easier because it pushes the wire through that first 90 degree turn and forces it into the Z shape of the bars that is the real bitch to get through.

I find that Castor oil works very well. It can either be left inside without damaging the wire insulation or can be washed out with any type of alcohol, if desired.

Great post, but where are the pics of the finished project? I have been wanting to switch to clubmans for a while but the wiring always ruined the look. I'd like to see the end result without all the wires in the way.

when changing bars, is it ok to not internally wire them, if they were that way beforehand?

I'll will post a pic when I get a chance. It looks really nice, especially if you want to use a remote MC or SS brake line, that way there is not a bunch of extra lines crowding up your area. It looks so clean it makes me want to replace all the bliky lights/guages and switch to a remote ignition.

And no there is no requirment to wiring them internally, in fact Kawi found it to be too much work and quit doing it on their later KZs. It is however a requirment if you want to be Super #1 Lucky Cool.