| Author | Message | ||
     Big_island_rider |
Finally got all the broken wire issues straightened out. Final total was six broken wires: Neutral light, Oil pressure light, Low fuel light, a Turn signal wire and two ground wires. Had a buddy who is really good at soldering come over and we ran all the wires and added about an inch to all the breaks then covered with shrink wrap. Took about four hours with no cuts, burns or abrasions  . Then got some 3/4" split poly loom from NAPA and covered it all up. Here are a few pics: After repairs and before loom covering.  Straight on view after loom cover. Notice the throttle cables are cable tied loosely to the steering head.  Side view of the same.  That is how I left it since turning the forks does not cause any binding or pinching and with the throttle cables out of the way, it should not break again. Since I was in there I also decided to put my KOSO volt meter in as well. Wired into the Instrument lighting and a broken ground. It is the wires coming in from the left in the first picture. Here are a few pics of the meter installed:   All totaled the cost was 4 hours work time, $4.07 for the loom, 2 glasses of Jim Beam Devil's Cut and 6 ice cubes. | ||
| Fotoguzzi |
nice pics, what year is that and do I need to worry about that on my 09? | ||
| Big_island_rider |
Fotoguzzi, Thanks. I have an 07. From my understanding it can happen on all years since the throttle cables and wiring loom go through the same small cover on the left side of the bike. More informed members (Froggy, Uly Man, etc) could guide you better than I. If you are not having any weird blinking lights or other handlebar electrical gremlins yet, I would say you are good right now. But I would get the throttle cables and wires away from each other. | ||
| Natexlh1000 |
I like that volt meter. Where is it from and how much did it cost? | ||
| Big_island_rider |
Natexlh1000, It is a KOSO Super slim. Comes in blue or red. Was $43 with shipping to Hawai'i. Got it from solomotoparts.com. (Message edited by big island rider on June 23, 2014) | ||
| Griffmeister |
Foto, all the Uly's have a ground at the steering head. Since this ground is for everything under the flyscreen those wires are constantly being flexed. Of course the wire breaks inside the insulation and you wouldn't know it until you pulled on the wire and found that it stretches. If something funny starts happening with your bike, this can be a good place to start. On my '08 the turn signals stopped working. At least it's an easy fix, the hardest part is getting your hands in such a tight area to work on it. | ||
| Etennuly |
I found that the triple splicers are the weak spot in the harness where they have to bend and move as the forks turn. They are both three into one cold clamp sealed wire splices. I did a single wire splice in the bundle moving the triple splicers into the fly screen space so that they would be in a place where they do not have to flex or move. That took the wire bundle's size down by four wires where it bends over the steering neck and through the bracket. | ||
| Pdento |
I just recently did the same thing. Mine had a break in the turn signal wire , heated grips ,lights in the speedo & the break light . They were all down by the steering head in the wiring harness . | ||
| Mnrider |
Nice job,man you didn't use to many ice cubes.  | ||
| Prior |
I had one harness replaced under warranty for the ignition switch cutting out, now the low fuel isn't working. Will probably follow the advice here and start relocating and unstraining a few things... Prior | ||
| Uly_man |
Good job Big-I. Just one thing since you spent time doing it. I found that the Earth wires are what pulls on the loom and if you leave it as it is it may damage the wires in the loom again. Or at least it did after I fixed mine. The second time I fixed it I made the Earth into a "coil of wire". This acts as a stress relief as the loom moves about. Works good and it has been fine ever since. Just cut the Earth lug off, solder on a coil of wire, add the lug and refit. I think it will save you problems in the long run as you have done all the hard work already. | ||
| Big_island_rider |
Uly man, The earth wire issue was a discussion between my buddy and I. We positioned the group of wires such that it had the least amount of movement and twisting when the forks are moved. I like the coil of wire idea and if I do "go back in" I will split the loom up past the ignition key lock and separate out the earth wires. | ||
| Xbimmer |
This has worked without further problems for 5 years: http://www.badweatherbikers.com/buell/messages/142 838/465647.html | ||
| Yan |
my apologies for bringing an old thread to life, but I am having similar issues, and wanted to double check - you guys suggest NOT putting the plastic cover back and stuffing both the loom and the throttle cables under it, correct? Because I can't see it in the pictures, but maybe it wasn't the final version. Thank you! | ||
| Big_island_rider |
Yan, Correct, DO NOT put the plastic cover back on. It created the problem on the first place. |
