Alright... I'm driving myself crazy with these handlebar switches not lasting. Either the switch goes bad, shorts on the handlebar, or the wiring gets pinched in the exit hole from the switch mount plate.

I've thought of two ways to solve this.

1. Cut a hole in the handlebar underneath the controls and run the wiring down through the handlebar. This will eliminate the pinched wiring, but may cause some lack of integrity on the handlebar...

2. Enlarge the size of the exit hole. This should stop the wire pinch/short/ground out nonsense.

That's all I've got. Anyone tried either of these ideas? Is there a better way? Also... does anyone know of a place to buy a good quality set of switches? Sooo done with these cheap tiny switches crapping out on me.

Thanks for the help

 

Back in the day off the top of my head I would say check Gary Bang for switches and wiring harnesses. Not sure if there even still around.

Love your shovelhead btw. I had a 73 many moons ago. Loved that bike!

Good luck...

 

I've done both - no failures... You can also take a good look at the switch terminals and bend them down somewhat so they don't short on the handlebars. Replacement switches aren't as good as the originals...

 

Aftermarket Chiwanese switches for the '73 thru '81 Switch housings are total Chiwanese Crap I have had the best luck rummaging thru boxes at swap meets for OE ones... Just the way of it... Some have switched to the '82+ controls. I agree that they are Marginally better, but, They sure are "Clunky"!!! I'll keep scrounging at Swaps...

 

Use smaller gauge wire and trim the blob after you solder , dremel comes real handy for this and deburring the inside of the holes in the handle bars where you keep shorting out . Next I put bit of black tape over the backs of those switches before clamping things together. Far as better quality switches good luck man , likes been mentioned do some box diving at swap meets looking for the old ones to refurb and use a lite touch with soldering iron too much heat wipes out them.

 

Agree + double heatshrink after solder and where they go through the bars if you're going internal.