Cable quality control

[heems]

Examining the bike I am noticing some "tears" in the plastic sheathing of some cables specially around bends. The bike is only 3 months old with 400 miles... Attached a pic for your reference. Should I be concerned and obtain new cabling?

 

[Reaper]

Mine did the exact same thing in the exact same place. Just had the dealer replace it when they replaced the starter.

 

[BWG56]

That sucks, had to be missed at the factory

 

[chacha]

You'll want that replaced or repaired...water and moisture will give you some corrosion on the cable down the road.

 

[heems]

I saw another thread (http://www.bigdogbiker.com/forums/technical/2275-starter-bendix-wire.html) about this issue as well so I went ahead and fix it as such:

1. Removed the top connection screw. I understand the cable is part of the starter itself and can't be simply replaced without needing a new starter. So we are going to do everything through this opening

2. Got a 3/4'' shrink tube and cut it to about 1.5''. Slide that to the bottom where the cable goes into the starter. I used a wider shrink tube since there is a wider "boot" at the starter connection point. Proceed to heat the tube and shrink it. Then I got a 1/2'' shrink tube and cut it to length for the remainder of the cable with some over lap with the earlier tube. Proceed to heat this tube now and shrink it.

3. Put the top connection back. I am going to apply some that "liquid tape" per above thread to the starter boot area to ensure the bottom shrink tube doesn't slide up.

 

[Chopper Dave]

mine was cracked also....just got done putting on a 3rd coat of that liquid tape! stuff works great!
here is the stuff that I used.....
Performix Liquid Tape Electrical Brush on Insulation