wiring harness for handlebar controls

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redzepp

redzepp

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May 10, 2010
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Does anyone know of a source for the wiring harnesses for the handlebar controls?
 
I may have some original ones from a '72 ..... PM me if you want ....
Craig
 
Good to have these eBay onesones avail but they are 5 wire only so will not do the 6 wire fitted to one side on the later bikes.
 
redzepp said:
Does anyone know of a source for the wiring harnesses for the handlebar controls?
Click to expand...
I've been looking forever. There are 5-wire cables that have a similar jacket and the wrong wire colors but I've never found 6-wire. I spend a lot of time getting the original cables looking as new as possible.
 
Does anyone know if it's possible to pull the wires out of the grey sleeving, as I aim to re-jig my switches over the winter, but want to keep the colour codes correct for each function (why make it easy for myself):rolleyes:
 
Why not put the wires inside the handlebars, as I did?

wiring harness for handlebar controls


You can purchase color coded wire in one meter lengths from www.britishwiring.com/

Slick
 
I have tried pulling at a single strand but it would not budge, instead to fix the issue I unsoldered all 6 wires and cut them all back until the problem wire was good, I then bewildered the 6 wires back, I lost 30mms but it still fits with Euro bars.
 
Had a look around, grey heat shrink tubing used to either cover grubby originals or to bundle new wires in the right colours looks feasible.
 
texasSlick said:
Why not put the wires inside the handlebars, as I did?

View attachment 7863

You can purchase color coded wire in one meter lengths from www.britishwiring.com/

Slick
Click to expand...
Hi Slick, and Happy New Year !!

Thanks for the suggestion. I have done that in the past, but my only reservation is that these switches have no anti rotation pin, so dropping the bike ( god forbid) can cause the wires to be severed. Are you using standard Lucas paddle switches?

Cheers,

cliffa.
 
kommando said:
Had a look around, grey heat shrink tubing used to either cover grubby originals or to bundle new wires in the right colours looks feasible.
Click to expand...
Hi Kommando, firstly Happy New Year!

I think I’ve come to the same conclusion, but it could be worse I guess.

Cheers,

cliffa.
 
cliffa said:
Hi Slick, and Happy New Year !!

Thanks for the suggestion. I have done that in the past, but my only reservation is that these switches have no anti rotation pin, so dropping the bike ( god forbid) can cause the wires to be severed. Are you using standard Lucas paddle switches?

Cheers,

cliffa.
Click to expand...

And a happy and prosperous New Year to you.

If you drop the bike (God forbid), you will have more concerns than severed wires. And what sort of anti rotation pin will survive a wreck?

My switches are the standard Lucas horn, dip, and magneto kill as fitted to the Atlas. No anti rotation pin .... just a clamp.

Slick
 
texasSlick said:
Why not put the wires inside the handlebars, as I did?

View attachment 7863

You can purchase color coded wire in one meter lengths from www.britishwiring.com/

Slick
Click to expand...
Thanks for the thought, but I am going as completely stock as possible on this bike. I have another which will be a cafe style.
rivera said:
This seller has replacement harnesses for both switches:
https://www.ebay.co.uk/itm/Lucas-Ha...=item2ecc4c2230:g:-gcAAMXQfvlSmQcz:rk:27:pf:0
Click to expand...
This is a good find! Thanks! I just sent a message to the seller to ask if the sleeve was roomy enough to add a 6th wire.
 
Thanks to all for the links and ideas. I believe that a path is opening for me.
 
Isn't the 6th wire an earting wire? The OIF BSA/Tri bikes had rubber mounted handlebars and when using the combined switch cluster from '72 on they needed an additional earthing wire. I believe you may get around with using a 5 wire harness on a Norton.

-Knut
 
mdt-son said:
Isn't the 6th wire an earting wire? The OIF BSA/Tri bikes had rubber mounted handlebars and when using the combined switch cluster from '72 on they needed an additional earthing wire. I believe you may get around with using a 5 wire harness on a Norton.

-Knut
Click to expand...

No its not an earth wire, there is a redundant one to feed the solenoid for starting (red/white) but that is needed if you fit Alton or CNW electric start.
 
(kommando beat me to it)
mdt-son said:
Isn't the 6th wire an earting wire?
Click to expand...

No, the 6th wire (white/red 'WR') is the unused electric start push button/switch wire.

mdt-son said:
The OIF BSA/Tri bikes had rubber mounted handlebars and when using the combined switch cluster from '72 on they needed an additional earthing wire. I believe you may get around with using a 5 wire harness on a Norton.
Click to expand...

Nothing in the OIF switch clusters requires a 'ground' to the handlebars and none have a 'ground' wire.
 
Last edited:
redzepp said:
Does anyone know of a source for the wiring harnesses for the handlebar controls?
Click to expand...

Grey PVC sleeving (in preference to shrinkwrap), the correct wire colours and bullets are available so why not make them yourself?
 
L.A.B. said:
Grey PVC sleeving (in preference to shrinkwrap), the correct wire colours and bullets are available so why not make them yourself?
Click to expand...
Please say where PVC sleeving somewhat close to correct is available - I haven't found it.
 
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