Harness Repair Advice

Ranger · Oct 11, 2019

Can I get some fix ideas on this harness for a speed twin please. I’ve been fixing a front end damaged bike and it wasn’t turning over. After some investigation I’ve found a break where the wires have crushed together in the accident just before the instrument connector. Purple wire.

Is there any recommended fix options here? Replacement harness is looking pricey.

Also thoughts on where to find a wiring diagram for a Speed Twin? I’m not sure if the purple is the culprit. But when squeezing the bunch of wires I got a temporary engine turnover.

Callumity · Oct 11, 2019

I would expose as much of the damaged area of wiring as I could then check each wire. It should be apparent from insulation crush damage which might have internal connectivity issues.
Starting worst first I would feel for breaks and insert a spade connector to bridge the break. Having proved all circuits I would protect with dielectric grease and heat sleeve before wrapping everything back up. It should be all you need. That sort of damage is highly localised.

freck · Oct 11, 2019

I’d be more inclined to repair each damaged wire by cutting out the damaged section and soldering a new piece of wire in, then insulating the soldered joint with a length of heat shrink.
If you’re not too confident of your soldering skills then practice with some spare wire before tackling the loom.