replacing stock handlebars.

[74 cb 750]

I wanted to ask all you garage pros for suggestions on the easiest way to remove the wiring from the stock bars. thanks!

 

[alfisto]

Well I'm not sure how it will work on your bike (larger size pictures would help) but on my little SS125 its relatively simple. The first thing you'll need to do is remove the left and right handle bar controls and detach all wires connected to them. Then you should be able to (with the help of WD40 or something similar) pull the wires through the handle bars, down and out if the hole near where the bars are bolted to the trees. Lubricant is the trick here!

 

[Big R]

Alfisto's right on with the lube. And try to pull with one hand while pushing with the other. And don't be afraid to twist them back and forth too. Oh yeah - try to get any bullet connectors through the holes in the bars first. Mine had bullets and a couple of those 3 and 4 way connections. Gotta save those ones for last.

 

[jonescafe72]

I had to completely cut up the bars on my 450 when I got it. Very slowly and very carefully with a cutting wheel.

 

[brianokc]

I unplug all the wires from the harness, remove the cables from the controls, then remove the handlebars and controls from the bike. Once that is done I carefully pull from the control side as I push from the part where wires are exiting. I also squirt a lot of wd40 down the bars to help it along.

When I am done I cut a hole in the bottom side of the controls and wire the bars externally with my new bars. Internal wiring is clean but it has no place on a daily rider, it shouldn't take half a day to change a set of hanndlebars!

 

[brianokc]

When I unhook the wires from the harness I take tape and I tag and number every wire I unhook and I write down what color wire went to which number. Makes it a lot quicker to wire it back together when I'm done