Horn wire keeps breaking
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Club Member
Joined: Jun 2009
Posts: 5,323
Likes: 37
From: NJ
Horn wire keeps breaking
This is the second time in about 3000 miles that my horn wire breaks at the horn connection as if it vibrated and ratteled off of the connection. I mean the wires actually break off from the tab connection that pushes onto the horn.
The tab connection stays on the horn and the wire is off...broken off.
I remember saying to myself the first time I fixed this "Man this wire is pretty brittle"....
I attributed the brittleness to the heat of the engine since the horn wire "lives" in the center of the two cylinders....
My engine doest shake any more than any other engine and actually I dont think it shakes at all much......but the horn wire is broken again.
It happened once when I had the cow bell cover....and again now with the skull cover just fyi...
Anyone else have this issue re-occuring?
The tab connection stays on the horn and the wire is off...broken off.
I remember saying to myself the first time I fixed this "Man this wire is pretty brittle"....
I attributed the brittleness to the heat of the engine since the horn wire "lives" in the center of the two cylinders....
My engine doest shake any more than any other engine and actually I dont think it shakes at all much......but the horn wire is broken again.
It happened once when I had the cow bell cover....and again now with the skull cover just fyi...
Anyone else have this issue re-occuring?
Last edited by Gliden; Mar 26, 2010 at 11:10 AM.
Elite HDF Member
Joined: Jul 2005
Posts: 3,968
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From: Lockport Township, IL
On most things, I solder and heat shrink, but on the horn, I crimp and heat shrink. When you solder that wire, the solder actually makes the wire stiffer and far less flexible. The vibration will cause it to break right tab connection. The wire will be more flexible and withstand the vibration better if it is not soldered. At least that has been my experience.
Road Warrior
Joined: Aug 2008
Posts: 1,474
Likes: 1
From: Acworth, Ga
On most things, I solder and heat shrink, but on the horn, I crimp and heat shrink. When you solder that wire, the solder actually makes the wire stiffer and far less flexible. The vibration will cause it to break right tab connection. The wire will be more flexible and withstand the vibration better if it is not soldered. At least that has been my experience.
Thread Starter
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Club Member
Joined: Jun 2009
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From: NJ
The nut had come loose causing the horn to shake under the skull cover.....thats what broke the wires this time.....
I must have forgotten the lock tight....
I must have forgotten the lock tight....
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Road Warrior
Joined: Jun 2009
Posts: 1,943
Likes: 3
From: NYC
it's obviously too short in length. replace the wire with a longer one and put a small loop in it for strees releif. You can use a tie wrap to secure the loop.
