running wiring through handlebars

[Headphase]

Just really throwing out a question.

I am 1/2 thinking about moving all the wiring from the handlebar switches, so it is inside the bars. Not the control cables (clutch or that), just the electrics.

I guess you'd just drill the bars where you wanted wires to enter and exit, feed the wires through, then plug the holes with some waterproof substance or other to keep the rain out.

My immediate thought was , wouldn't that massively weaken the bars, perhaps making them unusable?

Anyone done it, or thought about this ?

Like I said , I'm only toying with the idea at the moment, not actually doing it (yet :-D)

[Eli69]

i had an old honda that came with the wires in the handlebars. they entered through a slot in the center between the clamps. it did cause the bars to weaken enough that they were completely seperated. i knew about it and was used to it but my brother didn't and when he rode that bike once he went down. the bike was a total rat. my fault i guess but that's what happened. actually i thought it was a good idea but maybe that's a part that shouldn't be messed with.

[PAULYBOY]

If you made the holes small enough and kept them far away from the bends, that would be better, no?

[n1elkyfan]

It might also help if you sprayed some undercoating or even just some black paint inside to prevent rust.

[Ludeykrus]

I have bar-end blinkers, and ran the wires through the bars. I simply drilled a very small hole in the bottom of the very center of the bars; make sure you use a rubber grommet or at least some tape around the rim of the hole to keep it from stripping the insulation off the wiring and causing a short.

Other than that, it's not a big deal. Why WOULD it be a big deal, assuming you don't use a huge hole?

[tone]

I have run wiring through the bars before although i was only using the high/low switch the kill switch & the start button no problems apart from the hassles of space feeding them through

I would reccomend only doing it with steel bars & not ally ones & be aware of getting all the burrs from around the holes or they will cut through the wiring