I changed out the rear tire on my '07 Ultra today and found the wire raceway that runs along the topside of the fender to be severely abraided from tire rubbing to the point where there was exposed (bare) wire on one of wires. I cleaned it up and put some electrical tape over the bare wire, then put some aluminum tape over the raceway where the rubber cover was worn away but I am wondering if this is a common problem?

 

Mine did the same thing, i extened and re routed the harness so it runs on the outside of the fender but still hidden

 

Mine rubbed through the conduit but did not hurt the wire insulation. According to the SM the conduit was installed too close to the center of the fender by the MOCO about 1/2". I don't think it would have rubbed if it was in the right location. The conduit was pretty cheap < $6.00 but it is going to be a PIA to remove and replace it.

 

think about replacing the wiring which runs inside the fender--- get "flat style" wire, like from a pep boys trailer wiring kit.

figure out your connectors ( I actually use the trailer style plugs on my detachable tour pak)

the flat wiring can be "stuck" to the inside of the fender, running along the edge with rtv silicone.
just clean the inside of the fender first-- it's not so fiddly that you have to pull the wheel off- although you can loosen the bottom shock mounts and let the wheel hang if the bike is on a lift ( careful with balance)

if you use flat four wire, the most common, you have run, brake, left, right and use the chassis for ground

mike

 

Do you have short rear shocks, or lowered rear end? Stock bikes normally have plenty of clearance.