Next Project -- Fixing Handlebar Area Wire Wrap Failure

[Dana in Philly]

Hi guys,

Was washing the bike today (it was filthy), and noticed that the protective tubing around the wires coming from the handgrips is cracking and failing. Here are some images:









Suggestions? Is there a wrap that would work to protect these wires? Or do I have to disconnect everything and slide some tubing on there? What do you guys recommend?

[Droptarotter]

For a quick fix, there is two kinds of wrap available.

Split Loom and a Spiral Wrap, both work equally as well, but the split loom is a little easier to apply and I think it looks neater for this application.

Check electrical supply outlets or auto parts suppliers.

Cheers

[EZ-RIDER]

Hello;

This is what I have used
Weatherproof Cold Shrink Tape
Part #85274
Auto-Zone carries it, work great

[BMWR502]

I HIGHLY recommend this stuff. I just did this project on my '99 S 3 weeks ago. It's not super expensive, it was very easy to install, it looks really good, and it feels like it will last for the life of the bike.

I bought the 5/16" diameter, 10ft length. I ran it for both wire looms from the hand controls to the relay boxes, I had a little less than 3 ft left over.

Russell/5/16 in. dia. x 10 ft. Wrap-It wire sleeve (629090) | Wire Sleeve | AutoZone.com

[Meeni]

Used the same as proposed by EZ rider, for a damage to that exact same wire you show, 3 years later it is still working perfect.

[maverickma]

How is it applied? What does "cold shrink" mean?

Originally Posted by Meeni

Used the same as proposed by EZ rider, for a damage to that exact same wire you show, 3 years later it is still working perfect.

[Psychopath]

Prepare to find out nearly all of the wires are cracking and crumbling like that. At least that is what I found on my 99 R11S.

[EZ-RIDER]

When you wrap it thight against itself it bond without glue, it's made in England, similar to F4 tape but not rubber.

[omg1010]

This Amazon.com: Coroplast Fuzzy Fleece Tape As Used By Vw, Audi, Mercedes, Bmw: Office Products is what all German carmakers use for their wiring harnesses. Coroplast Ref. 8551

A suitable alternative would be this tesa® 51006 - Products - tesa SE

I have this coroplast stuff and I can say there is nothing better than that.

Brgds
Oliver

[JimMoore]

I cut away the old stuff and rewrapped it with cloth electrical tape from Radio Shack.

[maverickma]

BMWR502, that is a nice alternative, but my only concern is that there's a slit in it which could let water in. I actually bought tesa tape from a guy on eBay...$17 a roll but I like your idea and EZ-Rider's idea better. I'm on the fence on what to use.

A tip to keep wiring looking new is to them and any rubber parts with silicon spray a few times a year, especially before they are stored for the winter. Spray it and rub it in with your bare hands (just don't breath it in). My older bikes' wires all look like new and they are all high mileage. I also just bought 303 Aerospace protectant to try all over the BMW. Hopefully bring new life to all the wiring and dulled rubber & plastic bits. Another tip is to try to park it in the shade or under a cover if it's outside.

[Dana in Philly]

Meh. The wires look good. It's the protective tubing that's done for.

But OK, I take your point, and it is time for a new battery. Might as well pop up the tank and have a look around in the snakes nest under there.

Originally Posted by Psychopath

Prepare to find out nearly all of the wires are cracking and crumbling like that. At least that is what I found on my 99 R11S.

[BMWR502]

Understandable concern... the split in the loom doesn't just "butt" together though, it doubles over on itself and holds a very tight curl. Being behind the fairing, I would think it would be fairly difficult for water to be forced into the loom.

[maverickma]

BMWR502...hmm ok. So what did you do...take the tank off to get to both wire bundles?

[sgoodwin]

I've been using Wonder Wrap for years for projects like this where you don't want to take everything apart to wrap it. It fuses to itself almost instantly & only gets stronger as it sits, also totally waterproof. Comes in colors too but I've only used black

Miracle Wrap Home | Miracle Wrap

[kroberts]

Originally Posted by Psychopath

Prepare to find out nearly all of the wires are cracking and crumbling like that. At least that is what I found on my 99 R11S.

You beat me to it. I spent about three days stripping, cleaning, and rewrapping the vast majority of the harnesses on my bike after I bought it. The more I looked, the more I found. I bought a package of black zip-ties and re-secured them all when I was done.

[omg1010]

Hope you haven't tightened the zip-ties too much. That is a very common source/problem for the broken plastic stuff covering the wires.

There is a good reason why most manufacturers use that coroplast stuff ...

Brgds
Oliver

[maverickma]

BMWR502, hoping you see this post or the PM I sent you. Do you remove the old wire covering before you installed the Wrap-it split wire loom? I now have some wrap-it on hand, but it looks like it will only fit if I cut off the old stuff. Thanks. Doug