R1150GS: rotten wiring harness sheath: is there a fix?

[retroman]

The wiring harness sheath on my 2002 R1150GS has degraded to such an extent that it's now falling to bits, leaving the wiring exposed to the elements. I know this is an issue on bikes of this age.

I suppose the only real answer is rip the bike apart and replace the whole thing, but that's not really financially viable

Is there a fix that others have used successfully?

Headstock:



Underneath left handlebar switchgear:

 

[KMD]

Following on from a thread by Neil W in which he found exactly this, I bought a roll of electrical amalgam (I think that’s the right word) tape and have started taking out the perished sheathing and taping the loom. It’s an involved job and takes time, but I don’t know of a better way of doing it.

 

[Nick Marshall]

I’ve used this sort of tape in the past.

Pardon our interruption...

Mainly on the handlebars switch looms. Always on old R1150 bikes. It’s quite common for the loom covering to fall apart. Especially where it’s exposed.

You need to stretch it a bit for it to work.

 

[SBD]

You might try spiral wrap. It’s tough and will provide mechanical protection, but of course it’s not sealed.

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I guess you can buy it on Amazon too

 

[retroman]

You might try spiral wrap. It’s tough and will provide mechanical protection, but of course it’s not sealed.

Cable Spiral Wrapping, Plastic Spiral Wrap Cable Tidy | RS

Browse our range of High-Quality Cable Spiral Wrapping. Buy Plastic Spiral Cable Wrap. Ideal for keeping your cables & wires neat & tidy. Shop Today!

uk.rs-online.com

I guess you can buy it on Amazon too

Thanks for the suggestions. There seems to be a consensus.

I wonder if spiral wrap with a layer of tape might be a belt & braces solution ...?

Anyway, a job for the autumn I think (one of many on the list)

 

[SBD]

Meant to say, the spiral wrap is springy, obvs, try to find a size that’s quite tight on the loom, so it is stretched when you put it on. The more it’s stretched, the stiffer it gets, (oooh, err, missus) so if it’s going across the headstock you won’t want to over do it.

And the more it’s stretched widthways, the shorter it gets lengthways!

 

[Riceburner]

I had this on my Ed80 Rockster that I'm re-commisioning. It only seems to happen on one or two of the sub-looms (switchgear iirc), the rest is fine.

I bought some cloth wiring wrap tape from Amazon and just re-wrapped the looms. (I had the bike apart anyway).

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[retroman]

I had this on my Ed80 Rockster that I'm re-commisioning. It only seems to happen on one or two of the sub-looms (switchgear iirc), the rest is fine.

I bought some cloth wiring wrap tape from Amazon and just re-wrapped the looms. (I had the bike apart anyway).

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That looks excellent RB. I assumed that the whole loom under the tank etc would be rotten, not just the exposed bits. Good to know!

 

[albatross]

Has anybody ever redone the whole of the wiring loom to specs??
Are there any bods or companies out there who sell a complete loom??
I reckon after 25 years on the bike some scaffed and poor isolation, some crumbling with bio plastic being used…
Sometimes seems easier when doing an overhaul or refurb to use a complete new fully insulated loom…

 

[davegs]

The wiring harness sheath on my 2002 R1150GS has degraded to such an extent that it's now falling to bits, leaving the wiring exposed to the elements. I know this is an issue on bikes of this age.

I suppose the only real answer is rip the bike apart and replace the whole thing, but that's not really financially viable

Is there a fix that others have used successfully?

Headstock:

View attachment 337622

Underneath left handlebar switchgear:

View attachment 337627

When using this tape keep it in your trouser pocket so it warms a bit believe me as a retired sparks and using it all the time it makes it much easier to use.

 

[Riceburner]

Has anybody ever redone the whole of the wiring loom to specs??
Are there any bods or companies out there who sell a complete loom??
I reckon after 25 years on the bike some scaffed and poor isolation, some crumbling with bio plastic being used…
Sometimes seems easier when doing an overhaul or refurb to use a complete new fully insulated loom…

If I can't find all the bits I "repaired" when I stripped out the Meta alarm/immobiliser on my Ed80 I may have to look into this..... (Damn thing won't fire up....)

 

[dr nosh]

If Amazon is not your favourite source , these guys are my go to for vehicle electrics materials.

Cloth tape that I use is here:

https://www.vehiclewiringproducts.co.uk/c-192-tape/p-326-cloth-tape-adhesive.

With electrics, you have to be methodical or risk future breakdowns.

 

[Wrigsby1]

I have various parts of the loom that have been taped up/ have a degrading sheath and even in the worst shite weather it's not been a problem yet .. one of the advantages of there's looms is the connector quality starts off far superior to some manufacturers and so hold together better... I've had loom mysteries on Suzuki's and replacement ST13 looms just due to poor quality and finish...

 

[Paul G (BHT)]

I did my 1150 with none adhesive PVC tape, it did the job perfectly.

 

[Howard J]

It is possible, although a complete pain in the arse and time consuming, to take off the connectors one by one and re sleeve.

 

[Paul Young]

Look at what just appeared on my FB feed…

Hope it’s helpful

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[chopper_harris]

I had this issue on a recently acquired 2002 GS, I used this with excellent results

Self Amalgamating Repair Tape

• For pipes, hoses and electrical cables • Provides a watertight seal• Dielectric strength of 35kV/mm

www.toolstation.com

In some areas I was able to use a 24mm 3:1 heatshrink tube.
I will try to post some pics asap.

 

[theoneandonly]

do not use self amalgamating tape ...

it will collect every bit of grit it can find , when you want to take it off , it has become one with everything it touches.

use the fluffy cloth tape.

 

[Paul G (BHT)]

do not use self amalgamating tape ...

it will collect every bit of grit it can find , when you want to take it off , it has become one with everything it touches.

use the fluffy cloth tape.

Agreed.

While self amalgamating tape has its uses, I certainly wouldn't use it on wiring harnesses.

Use either the none adhesive PVC tape or cloth tape for the job.... my preference being the former.

 

[Udders]

I did my 1150 with none adhesive PVC tape, it did the job perfectly.

Just ordered some!