Handlebar sizes for 500

[Oddjob]

550 differ from the 500 ones that DS sells as they have the holes for the wires, why DS would sell different bars for the 2 models is beyond me, they are essentially the same bars. Grips were off a 1300 Ted and they should be just fine. The throttle tube setup should help with the amount of throttle travel the 500/550 has.

[McCabe-Thiele (Ted)]

550 differ from the 500 ones that DS sells as they have the holes for the wires, why DS would sell different bars for the 2 models is beyond me, they are essentially the same bars. Grips were off a 1300 Ted and they should be just fine. The throttle tube setup should help with the amount of throttle travel the 500/550 has.

So the 550 bars will have the serration centre points  100 mm apart so okay for the 500 - handy having the holes as well - my existing bars do not have an exit slot just a couple of holes on the underside that look too small for wiring - more like drain holes - they have nice rounded chrome coloured stop ends if I can get them out undamaged.

[Oddjob]

On the original bars there is a central slot between the serrations for the wires to exit. On the ends of the bars, someway in there should also be a slot for the wires to enter the bars but next to the slot there should also be a small hole, this is for the peg inside the switch to fit into, this positions the switch properly on the handlebars and also stops it spinning on the bars. The bars themselves should also have 2 punch marks next to outside edge of the serrations, these should be aligned with the gap between the clamp and the yoke so the bars sit at the correct angle.

Just in case you didn't know that Ted. AFAIK all Hondas have these punch marks, same as the ones on the pedals and pivot pins on the brakes.

[Trigger]

550 differ from the 500 ones that DS sells as they have the holes for the wires, why DS would sell different bars for the 2 models is beyond me, they are essentially the same bars. Grips were off a 1300 Ted and they should be just fine. The throttle tube setup should help with the amount of throttle travel the 500/550 has.

The 500 323 UK bars have a different rise to the 550 390 UK bars by about 1/4 inch from memory. Put the 500 UK bars on to a 550 and at the correct angle, the master cylinder is touching the clocks. Put the UK 550 390 bars on a UK 500 and as the clocks are lay flat, it doesn't effect anything. 

[Oddjob]

I have 500 bars on mine with 550 top yoke and clocks and it never hit anything, maybe it’s different market bars that did that. Even so, as Teds going 550 onto 500 he should be fine with the 550 bars.

Ted, can you post a pic of your switchgear especially from underneath to see if they’ve been altered to allow the wires to go outside the bars.

[Sesman]

The alignment pips are only on genuine original bars if I remember correctly.

[Oddjob]

Not on the DS copies then Phil, you’d think DS would specify that when he ordered them.

[Sesman]

Correct, certainly not on the ones they sent me.

[McCabe-Thiele (Ted)]

I have 500 bars on mine with 550 top yoke and clocks and it never hit anything, maybe it’s different market bars that did that. Even so, as Teds going 550 onto 500 he should be fine with the 550 bars.

Ted, can you post a pic of your switchgear especially from underneath to see if they’ve been altered to allow the wires to go outside the bars.

Both switches look original no sign of any file work or cutting out to my untrained eye.

As these look as thought the wiring is external might there be issues getting the wiring to fit through the holes - be nice to have the option if at some time I have to change the switches.
The 550 bars look the better option at the moment.

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.PXL_20230131_115401953 by Macabe Thiele, on Flickr
.switch by Macabe Thiele, on Flickr

[Trigger]

Not original 500 switches. More like 550 or 400/4 
On a closer look, they are for outsize cables maybe 550K3 or 500T

[McCabe-Thiele (Ted)]

Not original 500 switches. More like 550 or 400/4 
On a closer look, they are for outsize cables maybe 550K3 or 500T

Bryan did tell me they were US spec parts before I bought the bike.

[Oddjob]

550K3 switches Ted, not been altered by the look of them. Does it have the pass/horn button or just a horn button, can't see.

You have a choice, reuse them and run the wires outside the bars, replace them but then you have another choice, go with 550F switches that look like you already have or go back to the original 500 switches, in which case you're going to need to source a On/Off handlebar switch for the lights.

Another alternative is just to find the bodies off a 550F and swap the internals over. You only really need the bottom pieces.

[Bryanj]

I remember the bars being pattern, probably why the serations are too close together and the switches were a pair from my big box of used bits that work and had external wires as the bars were not strengthened for holes. The internal wiring may look nicer but can be a pain if you need to look into the switch in the future.

[McCabe-Thiele (Ted)]

550K3 switches Ted, not been altered by the look of them. Does it have the pass/horn button or just a horn button, can't see.

You have a choice, reuse them and run the wires outside the bars, replace them but then you have another choice, go with 550F switches that look like you already have or go back to the original 500 switches, in which case you're going to need to source a On/Off handlebar switch for the lights.

Another alternative is just to find the bodies off a 550F and swap the internals over. You only really need the bottom pieces.

Just a horn button like my 400 is - does the 500 K1 have external cables or internal?

[Bryanj]

Internal originaly