Wire Chaffing

36884 Views 15 Replies 10 Participants Last post by sanity, Sep 9, 2012

Aethelwolf

Discussion Starter · Mar 12, 2011

I got my Interstate back from the shop today. Originally they said I had a bad fuel pump. As it turns out the wire bundle that comes off the fuse box makes a 90 degree turn around a metal bracket. This bundle is only protected with a thin layer of tape. The vibration of the engine had caused this bundle to rub against the bracket to the point where two of the wires in the bundle were exposed and shorted out. The fuel pump wasn't bad, it had no juice. I would check this bundle out ASAP and make sure it isn't chaffing against the bracket or if it is, you have adequate protection to keep the wires safe. In the future you may see a recall from Honda for this problem.

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fireman dan

· #2 · Mar 13, 2011

thanks for the tip brother..im on duty right now but i will be home tomarrow and i will check it out tomarrow when i get time..glad to see it was only a minor problem

boogienightspkf

· #3 · Mar 13, 2011

Thanks for the head's up. I am new to my 1300, could you please tell somewhat specifically me where I need to look.

Again, thanks for letting us all know.

Aethelwolf

Discussion Starter · #4 · Mar 13, 2011

boogien, under the right side cover is your fuse box, take off the cover and follow and inspect the wire bundle that comes out of it as far as you can. Check to see if it's pinched or is tight up against anything, specially anything with an edge that can chaff it. If it is try to cover that part of the bundle with extra tape or heat shrink and inspect it on occasion for wear. Chances are at some point you might get a notice to run your bike into the dealer so they can do their own inspection and repair.

ghost

· #5 · Mar 13, 2011

will check this out thanks for the heads up............

Atyler

· #6 · Mar 14, 2011

Thanks, sory you had to go through puttng you bike in the shop

whynot

· #7 · Mar 29, 2011 (Edited by Moderator)

Thanks for the tip. You know... I left HD and went to Honda to try and avoid things like that. A trick I've used on other rides is to take a chunk of hose (usually radiator hose)find the right size and cut it to make it a split tube. Wrap it around the thing to be protected, overlap on itself and zip tie it in place. Works great for areas that are not in easy view.

What did they do at the shop to fix this?

whynot

· #8 · Apr 3, 2011

whynot said:
Thanks for the tip. You know... I left HD and went to Honda to try and avoid things like that. A trick I've used on other rides is to take a chunk of hose (usually radiator hose)find the right size and cut it to make it a split tube. Wrap it around the thing to be protected, overlap on itself and zip tie it in place. Works great for areas that are not in easy view.

What did they do at the shop to fix this?

Found the area you were talking about, seems like something that should've been noticed, pretty thin piece of metal that the wiring rests on. It is TIGHT in there. I took a piece of radiator hose about a 1.5" x 3" strip, managed to get it wrapped around the wiring and zip tied it on there. Hope it does the job.

Aethelwolf

Discussion Starter · #9 · Apr 5, 2011 (Edited by Moderator)

they didn't show me where it was and after all the trouble I had with guys, decided it wasn't worth the trouble to ask. Maybe you can share the spot as I would like to locate it myself. I can't see where they repaired it, but would sure like to do the same as you.

whynot

· #10 · Apr 5, 2011 (Edited by Moderator)

Aethelwolf said:
they didn't show me where it was and after all the trouble I had with guys, decided it wasn't worth the trouble to ask. Maybe you can share the spot as I would like to locate it myself. I can't see where they repaired it, but would sure like to do the same as you.

If it's where I think it is, it is only a few inches away from the fuse box. The harness goes around and on top of the bracket for the lower front, side panel grommet, fastener? Looked like a problem area to me?? I cut out the old tie down and had to wiggle, push and pull a bit to get the chunk of hose around it, had to use a fairly narrow piece as there is also a relay or something right there too. I can try and get a pic after work today if needed.

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ghost

· #11 · Apr 17, 2011

you can also use a piece of old inner tube to protect the wires

Reactions: 1

ghost

· #12 · May 1, 2011

checked it out today and mine has made a mark where the wireing runs parell to engine bracket dont know about fuse holder 90 degrae bend but will protect both with old inner tube.THANKS TO AETHELWOLF FOR POINTING OUT A FUTURE PROBLEM THAT MAY AFECT MANY OF THESE BIKES

Skyscraper

· #13 · Oct 3, 2011

Thanks for the tip. looked at mine the other day and I can see where that could be a problem, so I did the same to my harness as you had posted with a photo

jms412

· #14 · Nov 3, 2011

Thanks for the tip! I will check mine also.

markdotnet

· #15 · Sep 7, 2012

Here are some additional pictures that might help locate the area. I haven't done anything to mine yet so this is "stock".

Album: Wire Harness Chaffing

3 images
2 comments

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sanity

· #16 · Sep 9, 2012

Thanks so much for the pix! I'll be working on that this week.

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