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Fork Pinching Wiring Harness?

Old 07-12-2009, 04:56 AM
bigtim4's Avatar
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Join Date: May 2009
Location: Lawrence, KS
Posts: 21
Default Fork Pinching Wiring Harness?

A fairly odd problem-

When riding home on the highway at about 3 am from work my headlights cut out. Upon cutting out, the high beam light and both turn signal lights on the instrument cluster became illuminated. Turn signals work, albeit somewhat erratically. Brake light also still in good working order.

After taking the upper cowl off, I noticed the plastic zip ties that hold the different sections of the harness to the forks were broken. After researching the wiring diagrams, I think I've pinpointed the problem wires. It seems as though the harness is being unnecessarily pinched between the left fork and the frame when the handlebars are turned completely to the left.

Does anyone recall where on the forks the harness is suspended with the zip ties correctly holding everything together? Also, has anyone had the problem of have a section of the harness being pinched/frayed/broken by something similar?

Thanks in advance.
Old 07-12-2009, 12:38 PM
Senior Member
Join Date: Jul 2008
Location: NOVA
Posts: 778

I believe its about center between the upper and lower triples. As long as you put it somewhere where it won't be pinched again than you should be alright.
Old 07-12-2009, 11:08 PM
Aken's Avatar
July 2008 ROTM
Join Date: Oct 2007
Location: Milwaukee
Posts: 3,002

There's wire routing diagrams in the repair manual you can find via a quick search of this forum, they should help out nicely.
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