Handlebar wiring inside or out?

[SteveW]

My US spec 550 has the wiring from the controls on the outside of the handlebars. I had a set of old UK bars given to me which did not have the holes to route the cables through the bars.

Im about to order a new set of bars as mine are pretty rusty, but wondered what is correct for a 1974 K0 inside or out?

[Nurse Julie]

If I remember correctly, the wires on that model go inside the bars. I had a customer on to me the other day wanting a replacement, which I don't stock, as he had dropped the bike and bent the bars. His was a 1975 550 K0 USA model.

[SteveW]

Thanks Julie, I was hoping mine should have the wiring through the bars as I thnk it looks tidier.

[McCabe-Thiele (Ted)]

I bought a pair of UK bars for my 500 that had the holes for the wires plus the switch peg locating holes from Bertrum's Bits  last year - not too pricey either.

[Nurse Julie]

Thanks Julie, I was hoping mine should have the wiring through the bars as I thnk it looks tidier.

Yes, that would have been nice, as you say, it just looks tidier. I think the switch gear housing is different for the bars that have the holes for internal wiring, they have a little sort of half moon cut out on the underside so the switch gear sits around the bar before the wires disappear down the holes, I can't remember the switch gear for the externally mounted wires having the cutouts but I haven't any of that type of bars / switchgear here to check 🤔🤔🤔🤔.

[Bryanj]

I think you have that the wrong way round Julie, the cutouts are for external wiring the non cutouts for internal and both should have pegs to fit in holes on the bars to stop rotation

[Nurse Julie]

I think you have that the wrong way round Julie, the cutouts are for external wiring the non cutouts for internal and both should have pegs to fit in holes on the bars to stop rotation

You could well be right Bryan, it's been a while since I've had to fit switch gear ☺️☺️☺️☺️

[Bryanj]

Same here but i literaly tripped over a box of switches this morning!!!!

[Laverda Dave]

I'm with you on wiring on the inside Steve, it does look much tidier. Modern bikes these days are covered in cables from the handlebar switches, very untidy looking imho.

[florence]

having on the inside is a pain if you need to work on them though.  When I built mine I cut a small bit out of the switch body to allow the cable to go outside.  This was back in 1995 when switches were cheap and easy to come by.

[McCabe-Thiele (Ted)]

True, I suspect water ingress is less likely with concealed wiring.
You can still check the connections at either end.