Modern Vespa

I have fingers like sausages, small fussy stuff and my meat hooks rarely get along... so as I fumbled to run the stator wires up through the cases yesterday, an idea spawned.

I used a little zip-tie to group all the wires together. Then I ran a piece of monofilament from the outside of the case to the zip-tie. Placed the metal connections into the hole and then just pulled it all straight through via the mono. Worked like a charm.



If this is old hat to the rest of you, sorry. But, if it saves someone a few minutes of aggravation next time they have to mess with the stator wires, then I figure it was worth posting.

Meh.

Zip-tying is smart. I usually just use tape around the end so that there's no loose soldered tips to rub / catch on things, and then pull through with an old cable inner.

Working on my P200E that wasn't a problem. The taped bundle of wires was stiff enough to push through the passage.

Where I had a problem was fishing a new ground wire through the chassis from the rear to the horn cast junction box. I used a small steel cable I bought from a West Marine boat supplies store, about 3/32 or so. They are flexible, but they want to be straight. If you throw it on the floor, it will go to a straight line. And it can be pushed harder than a control cable inner. I shoved it down from the horn cast and it snaked its way right through the passage and came out under the gas tank. I put a little solder on the tip to keep it from fraying. When I pulled the ground wire through, I also pulled through two cords to use next time.

i used a long piece of twine. tied it to a washer, then dropped it through the tunnel, lifted the front of the bike up, and let gravity handle the rest.

then duct tape that twine to whatever you wanna pull through the frame and you're golden.

sometimes the old neutral switch wires are left around and you can use those for stuff

Similar for me, wrap the ends in electrical tape or similar, drop a string through the tunnel, tie it and pull them through.