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Steering stem job GL1500: Turn signal cancel switch wires

1372 Views 6 Replies 6 Participants Last post by  Hawker22, 
Oldshack
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Ok you guys that have done this job on the 1500... While pulling on the wire bundle from the top while disassembling, the safey clip on the wire connector broke allowing the wire bundle to come apart and be disassembled. Going back together with it the bottom wire going up through the stem is too short to go through the top and connect and the top end of the wire bundle is routed such that it is too short to go down through the stem and out the bottom to connect the connector. It was obviouslyconnected at the factory and strung up from the bottom before the wire bundle was even mounted and routed on the bike. What did you guys do? I am thinking at this point to take the bottom switch and wire assembly out and cut each wire and add about 6 inches to each wire so that I can feed it up and out the top of the stem to connect it then feed it back into the stem after its connected.
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SpiderBob
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Release the bundle ties at the front fork tube, then slide the cover (apply some soap) up the wire and push the connector down the tube and out the bottom, thenconnect and reverse the operation. ;)
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jimsjinx
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I did the same job on my trike to adjust the head bearings. I also had the connector problem. I found that, if you slide the boot FAR away from the entry point(top), this allows enough wire length to connect the sockets at the bottom of the triple tree. I found all this out here, after making a wood dowel rod to feed the connector from the top.Too long to explain, but it was a 14 carat pain in the backside! :XGive it a try, with some lube (soap,silicone spray,etc.), the boot will slide out of your way. Good luck, and don't do what I did and pinch the throttle cables when you retorque the handlebars!!:shock: jimsjinx
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Oldshack
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Thanks guys, I will try that. Bobby
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D
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I loosened the wire ties like Spider Bob indicated, pushed the connector out the bottom and reconnected it together. Of course this included removing the turn signal cancellation unit at the bottom of the steering stem.
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wingnut
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I've done this a few times and it's always tight. Cut the ties, slide the boot back and pull as much slack from the fairing end as you can. You might still not get the connector all the way down the tube, but it will go far enough so you can get a screwdriver in and pop the clip.
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Hawker22
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Agree---- Having just done that job, I eventually had to release the cable/wire connectors and got it far enough down to be able to work the clip. I thought about adding a length of wire to the bottom, but opted not to because of concerns about changing the resistance of the lead.
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