Topic: Front brake light wire keep breaking!!!!!

[grumpy]

The ground wire off the front brake switch keeps breaking - like every couple of weeks.

I figured it was the 40 year old wire getting brittle so I spliced in couple of inches of new 14g stranded and it's STILL breaking.

What the hell?

Any ideas?

[Mainerider]

Is it snapping by being routed improperly  or is it melting and then breaking?  Have you checked the ground for high resistance?

[fishslayeryo]

good point on the routing...also make sure it's long enough, but this would only be an issue if routed wrong....turn the bars the furthest each side and see if it's getting yanked.

[grumpy]

OK, I think I found the problem (s)....

1) I like to solder rather than crimp my connector and 2) I used pre-tinned, stranded wire.

So when I soldered the bullet connector the solder wicked up under the insulation and fused the strands turning into essentially solid core wire... and solid core doesn't like to be bent as when turning the bars. So it done did break.