Just got my Rad bars today! Question, did you run the wires inside? Anyone else? I would love to see a closeup pic of a bike with the wires run, to see what it will look like, and if it is worth the extra hours. Most of the pics in the gallery look like the wires were NOT run inside.

 

Did not run them inside, yet. They look good on the outside for now. Dont know if the time spent putting them inside is worth the change in appearance. Just having the bars is such an improvement, in looks, I dont notice the wires so much.

 

I am curious about this "wires inside" stuff. Does that mean that the electrical wiring goes inside the handlebar somewhere close to the handles, and then comes ut behind the headlight arrangement somewhere? Or is there a way to rout the wires into the handlebar *inside* the control package by the handle? If not, I get the impression that the entry point into the handlebars would look worse than having the wires outside all the way down.

 

It is worth the pain to run the wires through the bars. You did right removing that pos wire stay, I also used my Dremel.
Do use a flat washer under the bars, on top of the triple tree. Even better, get a thicker one than stock. If you don't use a washer, you will have lots of vibration.
You might want to do a search for "Radius bars", there is a lot of info on installing.

 

Radius Bars! I originally had the wires running internal, but had to pull due to the non-professional install I did the first time. The inside of the bars are rather sharp and some of my wires got striped down and grounded out. I am in the process now of redoing the internal routing of the control wires again with shrink wrapping (protective wrap). If you go with the internal wiring you will have to add extentions on the control lines, especially the clutch side. The holes for the internal wiring are very well hidden and do not look offensive in any way. The hole are right below the control housing and exits on the inside part of the Rad Bars near the triple tree. The Warrior looks 100% better with wires run internally, cuts down on the Yamaha Clutter mess with all the cables, lines everywhere. You must use washers to keep the bars from compressing the dampener's. You will experience very numb hands on any extended road trip. I put large flat washer on bottom of triple tree and large locking washer on top of triple tree. This was a very noticable difference in vibration. I also had to get longer bolts to accomadate the extra washers. More important is to torque the bars down, do not over tighten, this also has an affect on vibration. Boogiman has pictures in the gallery with the wires run internally. If you look at my pic's there might be a few pic's with one side (throttle side) run internally. I hope this helps. It is worth the 5-6 hours to do the internal routing. Gives it that clean custom look!

 

Spoke to Barons today about the washer question. I was told not to use a washer, other than the one lock washer supplied. He said they are coming out with a poly bushing soon to replace the stock rubber. He says the vibration is less with this bushing. Didn't seem logical to me.

 

Started the wiring job last night to do the internals - so far so good! But yeah, it's a pain in the a$#. It is nice to be able to pull the bars cables and electrical housings to do the job in the living room, not the garage - it's about 15 degrees in MI right now.

 

Yes, I would highly recommend doing it in the most comfortable location available. Like in the house in your favorite recliner or in a nice warm workshop. It can be very frustrating at times especially routing the wires internally. Good Luck! You will be happy with the look!

 

DarkStar, is there enough length for the internall wiring, without adding any more wire throttle or clutch cable's

Mac

 

Mac,
You are talking about the Control Lines, correct? If so, No, the clutch side needs another 8-10" I got by with the throttle side, but would recommend adding another 5-6". If you are not talking about the control lines then Yes, you will have enough length for the throttle/clutch lines.
The lines I am talking about that run internally are the switch lines or control lines. These are the switches like the horn, turn signals, starter, kill switch etc....

 

A word of caution for anyone doing the internal wiring - file the corners of the clutch perch. They are sharp! While doing the work, I slipped with it and cut 3 of my wires - after all the crap you have to go through to get those wires in, believe me, if you do what i did, the neighbors will here the cussing!

 

65Tux,
Did you shrink wrap those wires? If you did not, you should. I routed those control wires with just electrical tape the first time and eventually they cut through and grounded out. I am redoing the whole set internal wiring this weekend.

 

DarkStar,
Yeah, i started with e-tape that didn't work at all - way to easy to cut. going to pull it out and redo it the right way this weekend - or some time in the next few months - i hate michigan this time of year!

 

Cool, I am doing the heat shrink wrap internally, then where the lines exit I am running stainless braided lines the rest of the way to the head light.