Help (ignition, Aprilia Tuono)

I have done so much cornering recently, that one of the wires to the
ignition has worn (the red one). This results in a non-running bike. Any
tips on how this can be mended the easy way? From the ignition, I have about
1 inch left. First thought was soldering, but, since the wires move about a
bit, it will become undone again in no time, I fear. How the f**k do I
remove the ignition from the bike, the non-pikey way.

 

How about crimping the two ends together using a butt connector? [1]

[1] I know this sounds a bit BGN-like, but that's really the proper
electrical terminology!

 

First, I'd find the pinch point that is causing the wire to fray. On the R-
GS it's quite common for the apes in the factory to be over-enthusuastic
with the cable ties, so that a random wire rubs the frame as the bars are
turned. Some people have spent months trying to locate an intermittent
electrical fault.

Once you have released the wire from being under tension then *add* a
section of wire. Soldering is the best method if done by someone with a
clue. I'd use some shrink tubing to give insulation and apply some self
amalgamating tape to make it waterproof. Ensure you add a long enough piece
of wire so that there is not tension when the bars are moved from lock to
lock.

 

Solder in a slightly longer bit rather than join the two ends together.
You'll have to faff about trimming and shrink-wrapping the join etc but
it'll probably be worth the effort.

 

Wot 'e sed, but I wouldn't bother with the self-amalgamating tape,
just a lot of overlap on the HS tube.

 

That's the only way I know how to solder a broken cable.

--
Lozzo
SV650S K5, ZX-7R P4, CBR600F-W, SR250 SpazzTrakka, SR250 Project
SpazzCaffer
I see a bright new future, where chickens can cross the road with no
fear of having their motives questioned

 

Western Union splice?

 

I tend to just mesh the strands and give them a little twist to hold
it. I don't wrap little bits of wire round to hold it all in place.

--
Lozzo
SV650S K5, ZX-7R P4, CBR600F-W, SR250 SpazzTrakka, SR250 Project
SpazzCaffer
I see a bright new future, where chickens can cross the road with no
fear of having their motives questioned

 

Is what was done:

http://www.tessco.com/products/imagedisplay.jsp?itemID=32407

I will however see what the cost will be of new wiring to the ignition. I'd
hate to be halfway to Orleans in a couple of months and suddenly have no
power anymore...

 

Using the patented Mavis Beacon "Hunt&Peck" Technique, Spete

I should, IIWY.

It would be terrible to burn to death before reaching Orleans, when with
care you could have maid it.

 

<groan>

--
Krusty

'03 Tiger 955i
'02 MV Senna (for sale) '96 Tiger (for sale)
'79 Fantic Hiro 250 (for sale) '81 Corvette (for sale)

 

Got to watch out for the wiring arcing.