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Old Apr 18th 2016, 05:11 AM   #1
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Post How To Safety Wire Your Bike

A couple of guys on this great forum showed some interest on the topic "safety wiring". So I thought let's start a new thread about this.

First some basic rules:
Do not kink, nick or mutilate the wire. Use some high quality INOX bright drawn steel (sorry, in german it's called "blank gezogen". I'm sure Phl can help). Do not overstress the wire or twist it too tightly. Install the wire that it will tend to tighten the bolt. Try to install it closely around the bolt and not over it. Best is to tighten the wire when twisting, after installation there should be some tension on it. Use a good twisting tool (I use Stahlwille, it does not hurt the safety wire). Upper wire should enter the bolt's hole. Leave at least 6 twists on the free end. Make sure nobody gets hurt from the sharp ends. Try to find the shortest distance, the shorter the wire is placed, the better. Don't hestitate to redo the wiring if it looks shitty. It takes a bit of time to get it done nicely. You'll see on the pictures below that a lot of wirings on my bikes can be improved. I am an impatient person! Do not retorque the bolts to get a tension on the wire: this is a core sin and will be punished in purgatory!

In the military service, we had exact specs about twists per centimeter, ccw or cw twisting and so on. IMHO this should not apply to motorcycles, too many rules make life just more difficult.

Okay, here is my first example: The Oil Plug
I really like the NCR style oil plugs (image 1). But they have some disadvantages. The big 14mm hex allen hole prevents the aluminium plug from being hurt, but nobody on the track has such a key in his toolbox. And the big hole tends to collect a lot of water. Also the position of the safety wire hole is always wrong

So i bought a Titanium oil plug from MotoCorse, installed it on the bike and marked its position after fully tightening it. Then I milled two slots into the plug and drilled a safety wire hole (diameter 1.5mm).

Now I can secure the plug the right way, the wire really prevents the plug from loosening. Since it's Ti, the hex hole can be made smaller and no surface protection against corrosion is needed after this work.
Attached Thumbnails
How To Safety Wire Your Bike-oil-plug-1.jpg   How To Safety Wire Your Bike-oil-plug-2.jpg   How To Safety Wire Your Bike-oil-plug-3.jpg   How To Safety Wire Your Bike-oil-plug-4.jpg  
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Last edited by Gecko; Apr 19th 2016 at 11:11 AM.
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Old Apr 18th 2016, 05:34 AM   #2
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If the wire has any other contact to other surfaces than the bolts attached, I use shrink tubes for protection from unwanted scratches. And it's a cheap way to get a NASA look

1. Front caliper bolts
2. Blockoff plate
3. SL rear hugger mounting bolts
Attached Thumbnails
How To Safety Wire Your Bike-st3.jpg   How To Safety Wire Your Bike-st2.jpg   How To Safety Wire Your Bike-st1.jpg  
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Old Apr 18th 2016, 05:58 AM   #3
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Sometimes I use safety wire just to mark that bolts are properly torqued, then wires just prevent bolts from getting lost (very good in the monocoque/airbox ).

1: LH side h-cyl cover
2: Excenter pinch bolts
Attached Thumbnails
How To Safety Wire Your Bike-dsc_0007.jpg   How To Safety Wire Your Bike-dsc_0003-1-.jpg  
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Old Apr 18th 2016, 06:03 AM   #4
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Old Apr 18th 2016, 06:13 AM   #5
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I Ride: 1199 SL, 1199S Tri, 1299S Anni, MV Agusta F4 750, M1200S, M696, Husaberg FS650e, Petronas FP1
And often wires just help me installing small nifty little bits from falling into the vast unknow space between engine and exhaust. Front under the dashboard is also a very unplesant space to loose a bolt....

1: Pieces to mount the shift tech subrame
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How To Safety Wire Your Bike-dsc_0030.jpg  
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Old Apr 18th 2016, 06:16 AM   #6
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nice work!

i am waiting for the first asshat to say that you just wanna show off
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Old Apr 18th 2016, 06:31 AM   #7
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Here two examples of "I don't want to lose these bolts"...
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How To Safety Wire Your Bike-1.jpg   How To Safety Wire Your Bike-2.jpg  
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Old Apr 18th 2016, 07:39 AM   #8
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is there something like Ti-safety wire? i guess not - you'd have already used it, right?
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Old Apr 18th 2016, 08:37 AM   #9
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Gecko,
Please do us all a favor and just start a thread containing nothing but pictures of your bike.

Wait a second--are those cast cheesemetal washers I see under the Ti bolts in the underseat bracket photo?
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Old Apr 18th 2016, 08:48 AM   #10
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Can anyone recommend a jig for drilling oem bolts? How is the motoD jig? I'd rather spend my cash on track time and slicks versus buying pre drilled bolts.
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