Topic: Replacing the harness sleeve to headlight?

[jakec]

This is something I’ve never had to replace before. The main harness connection into the headlight bucket has the (previously) soft non shrinking sleeve. On this bike the sleeve cracked in half and it had sharp edges that were rubbing the wires every time I turned the bars. So I decided to cut it off and replace it. I bought the correct sized tubing from vintage connections. But I can’t see a possible way to put the wires in, without cutting off connections at the end, or cutting wires on the bike end and butt connecting them (hidden under tank).

Is there any way to get these thru the sleeve without cutting any original wiring? The bike is all original so I don’t want to redo all the connections. Even though I have the stuff to do it I would rather not

[bryanj]

One wire at at time with soap and patience

[jakec]

Have you done it that way? The double and triple connectors barely make it through as it is.

[bryanj]

Yes i have, start with biggest then work down, sometimes helps if you flatten the sleeve

[seanbarney41]

I tried it and had exact same realization...this ain't gonna work!  lesser man than Brian J am I apparently.  I just used the next bigger size with two short pieces of heat shrink on the ends to suash it down so the sleeve can't slide around...not ideal

[newday777]

Have you done it that way? The double and triple connectors barely make it through as it is.

Did you put a pull wire on each wire to aid getting them through?

[Don R]

 Straighten and align them as much as you can, stagger the ends with the big ones through first. Wrap them tightly in a couple places. Use a pull string too.

[Don R]

 If you're not worried about originality look up techflex split woven wire loom.

[jakec]

I am worried about originality, I would rather just do electrical tape than cut something. I tried to stagger the connections so only one would go thru at one time, but like I said, one single triple connector takes up the whole width of the tube. I could probably get 3-4 wires through, but there’s like 12 or so. I assume in the factory they put the connections on after the sleeve.

[PeWe]

Braided expandable cable sleeve another alternative. It will expand when pushing it together, reduce when stretching it.

The model I mean is not open along its lenght.

[pjlogue]

I agree with Bryan and Don.  You should be able to pull each wire through with a string starting with the largest connector end.  I would straighten any kinks along each wire and clean the wires to get dirt off them.  I would then get a stiff wire or coat hanger to act as a shuttle to shove the string through the plastic sleeve and attach the string to the largest connector and pull it through and then the next largest connector and so on.  I use wire pulling lubricant when I pull wires through handlebars.  I have pulled a bundle of 8 wires with connectors through 7/8" bars (5/8" ID) with little problem.  It just takes patience.

The plastic sleeve in your picture looks quit thick.  If there is any real stiffness in it I don't think it is what you want since it is in a high flex situation.  If you want to keep things original you might try and find a used harness off eBay and use that plastic tube.  Just a thought.

-P.

[Kevin D]

A while back I replaced the brittle black tubing on gauges, handlebar switches, and half the main harness from under the tank forward into the headlight shell.
At the electrical supply there was a healthy supply of 3M shrink tubing in various diameter in 3’ or 4’ lengths.

For the main harness repair I chose a shrink tube that matched the original when shrunk, the initial diameter was maybe 1.5 times larger, maybe more, hence no sweat to get wires through.

A roll of Scotch 33+ is needed to attach the pull wire and to hold the staggered tapered bundle of the connectors.
Shrink to suit.

No sweat and no problems 15+ years later.

You’ll get it jake

[Don R]

 Once you do a set of handlebar wires this looks like child's play. Especially when the inside of the original bars have a little rust in them.

[bryanj]

Don is correct, handlebars are a whole new awkward story

[Kevin D]

Some use New Dawn to help getting around the bends.
There is professional grade wire pulling lube at Home Depot.

Maybe I tried to shove the handlebar wires through, unsuccessfully.
Second try with a pull wire and lube, all good.
Don’t know exactly what I did 15 yrs ago but there was no blood toil sweat or tears involved.

[jakec]

I’ve done handlebars 100 times, the difference is those are all male bullet connectors, whereas this is all female (much larger). I guess I’ll start by cleaning everything, and try the string. That is what I was thinking as well, pulling through with fishing wire or similar.

[seanbarney41]

All you guys that are thinking this is like putting the wiring into handlebars...nope, not even close.  Like Jake, the only way I can see the factory doing this is to crimp the connectors after the sleeve is already on.  If BryanJ says it can be done with the correct size sleeve?!...I dunno, I would have to look again.