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@zachyzach avatar
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'64 VBBs, '74 BMW R75/6 airhead, '74 Bultaco Alpina 250, Lambrettas + projects
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'64 VBBs, '74 BMW R75/6 airhead, '74 Bultaco Alpina 250, Lambrettas + projects
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Almost done installing a new wiring harness in a '64 VBB2 restoration. Only challenge so far is the narrow tube that leads to the rear brake at back of the VBB frame. It's super tight -- just a 1/8 of an inch or 3 16ths, etc. So, it's a teeny channel. Barely room for the 3 wires that connect to the brake, much less for the shrink tubing that surrounds the wires.

If I wrap the lot in thin tape, I don't think it will fit through, and the tape will get jammed too.

What have folks done here to get the wires through and keep them in good shape? Strip out the black protective sleeve around the wires and leave them bare? Any other tricks? Just curious if I'm missing any solutions before I remove the protective sleeve. Tks
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UTC

Molto Verboso
1958 Allstate 177VMC, 1962 Allstate, Yamaha Vino 70cc
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Posts: 1980
Location: Philadelphia
 
Molto Verboso
1958 Allstate 177VMC, 1962 Allstate, Yamaha Vino 70cc
Joined: UTC
Posts: 1980
Location: Philadelphia
UTC quote
Just ran into this on my friends 62 Allstate.

My 58 Allstate somehow fits all 3 wires. His wouldn't. So what I did was just grounded the taillight wire under the glovebox cowl bolt. Only have to remove the top one so it's easy. Crimp on a proper fitting then sand under the bolt for an A plus ground. Easy peasy
@chandlerman avatar
UTC

Lucky
76 Sprint V, 63 GL, 62 VBB, 05 Stella, 66 Smallstate, 79 P200E, 66 Lammy S3
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Lucky
@chandlerman avatar
76 Sprint V, 63 GL, 62 VBB, 05 Stella, 66 Smallstate, 79 P200E, 66 Lammy S3
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UTC quote
I've just stripped the sheathing off when I've had to deal with that, and it's still brutal.

Get ready to cuss a lot.
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@zachyzach avatar
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'64 VBBs, '74 BMW R75/6 airhead, '74 Bultaco Alpina 250, Lambrettas + projects
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@zachyzach avatar
'64 VBBs, '74 BMW R75/6 airhead, '74 Bultaco Alpina 250, Lambrettas + projects
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UTC quote
Thanks for the tips. i'll sleep on it and commence the cussing tomorrow.
@chandlerman avatar
UTC

Lucky
76 Sprint V, 63 GL, 62 VBB, 05 Stella, 66 Smallstate, 79 P200E, 66 Lammy S3
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72 Days Since Last Explosion
 
Lucky
@chandlerman avatar
76 Sprint V, 63 GL, 62 VBB, 05 Stella, 66 Smallstate, 79 P200E, 66 Lammy S3
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72 Days Since Last Explosion
UTC quote
Run a lead line, then use it to pull the rest through. You may want to lubricate the wires, too, if they don't want to slide through with more than a little persuasion.

And as you're probably already aware, the angle of the tube into the cavity is such that the wire will tend to try and hang on the edge, so you have to hold it up so it doesn't catch.

Oh, and expect to make a blood sacrifice or two while you're doing it. Vintage scooters love blood.

Good luck!
@christopher_55934 avatar
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Ossessionato
2007 Stella 225
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Posts: 3547
Location: Rochester, Minnesota
 
Ossessionato
@christopher_55934 avatar
2007 Stella 225
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Location: Rochester, Minnesota
UTC quote
Run a lead line as suggested then pull some good waxed dental floss through. Wrap dental floss around wires to keep them together and pull dental floss and wiring back through.
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Addicted
1974 Rally 200, 1974 Rally 200 with sidecar, Vespacross bike
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Location: Atlanta
 
Addicted
1974 Rally 200, 1974 Rally 200 with sidecar, Vespacross bike
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Location: Atlanta
UTC quote
Bikes that had the steel guide tube didn't use the sheath. I recommend running an old clutch cable in there to remove any junk that may have built up (rust, old wiring, etc) and then use
a little grease on the wires.
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@zachyzach avatar
UTC

Addicted
'64 VBBs, '74 BMW R75/6 airhead, '74 Bultaco Alpina 250, Lambrettas + projects
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@zachyzach avatar
'64 VBBs, '74 BMW R75/6 airhead, '74 Bultaco Alpina 250, Lambrettas + projects
Joined: UTC
Posts: 572
Location: Western Mass., USA
UTC quote
Mattgyver wrote:
Bikes that had the steel guide tube didn't use the sheath. I recommend running an old clutch cable in there to remove any junk that may have built up (rust, old wiring, etc) and then use
a little grease on the wires.
Thanks for the knowledge on this bit of frame history. Sounds like congress will not be achieved between the rear sub loom sheath and the narrow brazed on tube from this era. I'll remove a bit more than a foot of the sheath and wires should travel through the tube fine.
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