Cable And Harness Routing - Honda XL200 2001 Shop Manual

GENERAL INFORMATION
CABLE & HARNESS ROUTING
Note the following when routing cables and wire harnesses:
• A loose wire, harness or cable can be a safety hazard. After
clamping, check each wire to be sure it is secure.
• Do not squeeze a wire against a weld, or the end of its clamp.
• Secure wires and wire harnesses to the frame with their
respective bands at the designated locations. Tighten the
bands so that only the insulated surfaces contact the wires or
harnesses.
• Route harnesses so they are not pulled taut or have excessive
slack.
• Protect wires and harnesses with electrical tape or tubing
where they contact a sharp edge or corner. Clean all surfaces
thoroughly before applying tape.
• Do not use wires or harnesses with damaged insulation.
Rapair the wires by wrapping them with protective tape.
• Route wire harnesses to avoid sharp edges or corners.
• Avoid the projected ends of bolts and screws.
• Keep wire harnesses away from the exhaust pipes and other
hot parts.
• Be sure grommets are seated in their grooves properly.
• After clamping, check each harnesses to be certain that it is not
interfering with any moving or sliding parts.
• After routing, check that the wire harnesses are not twisted or
kinked.
• Wire harnesses routed along the handlebars shoud not be
pulled taut, have excessive slack, or interfere with adjacent or
surrounding parts in any steering position
• Do not bend or twist control cables. Damaged control cables
will not operate smoothly and may stick or bind.
O – Correct
X – Incorrect
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