Wire sleeve repair

[sstein]

These are the plastic sleeves that cover the wire bundles coming out from under the head lamp. I've got a few totally shredded ones on my '02 r. What is the recommended repair other than electrical tape?

[Oilhead]

There was a service bulletin on this several years ago. They installed some kind of protecter on it to prevent the bundle from chafing. I remember taking in my bike for a fuel system related recall and the dealer told me there were a couple of open service bulletins on my bike and that he would perform it no charge; and one of it was the the forementioned wiring harness protector.

[Sunbeemer]

I replaced those with fireproof split-plastic wire-loom sheathing, like the type you see in cars.
Probably doesn't need to be fireproof, but that's what I had on hand.
I did both sides going forward from the tank using a couple pieces on each side to keep it flat enough that it wouldn't touch the sliders steering lock-to-lock. I similarly encased the headlight and instrument cluster wiring.

I also moved the horn under the headpost to eliminate chafing by drilling and tapping a 1/4" X 20 tpi hole through the bottom of the front edge of the aluminum headpost casting and bolted the horn bracket (sans the hinged adapter bracket) inside (underneath) the headpost.

This is better

[omg1010]

Use this or similar: http://www.autoobsessed.com/shop/wiring ... p-795.html

Brgds
Oliver

[Laserr Boy]

I really like 3M Scotch 23 self amalgamating tape. It is expensive however it makes a waterproof seal. I first used it on offshore sailboats and have since used it to seal wire repairs on heavy equipment when it wasn't possible to use heat shrink. Unlike regular electrical tape it does not absorb water and leaves no sticky residue when removed.

[sjbmw]

Cut the wire tie where the left and right control wires sheaths meet directly behind the headlamp.
It's a wire pinch and break waiting to happen.

(I used eletrical tape, tbw)

[Sunbeemer]

I originally used self-vulcanizing (aka amalgamating) tape to repair my disintegrating wire sheaths, but it only lasted a couple years in our Florida UV-intense sunshine, so I resheathed all the bundles with the split plastic loom I mentioned above which has lasted for over five years.