Gentlemen: I ask this without reference to a bike to look at, so bear with me if the question seems stupid. The smaller wires that are commonly breaking, (neutral light indicator, side stand safety shut off switch are two that come to mind) Are these single strand core or multistrand braided wires, copper or aluminium, and where in general with respect to their points of fixation do they break -near one end or the the other, in the middle where they turn sharp angles to emerge from under a casing or navigate a corner, etc, or at a point of friction with some "hard" part -frame or other metal part.?
I know there have also been battery ground cable failures -are these at the point of fixation of the braided rope cable to the terminal lug? And is the main wiring harness a flat automotive type wiring setup with conductive elements running side by side in a flexible flat ribbon, or is it a round profile running the length of the bike? If found, cloth wrapped or plastic molded? The answers to these questions may point the way to some very simple solutions. Another thought I keep coming to is that wires (especially single strand) , or any structure for that mater, tend to break (under repeated cycles of movement) at the points of junction between fixed and mobile segments, or also at points where the calibre changes. Tapered sleeves of rubber molding to support the wires where they take off from a point of fixation may help disperse the flexing forces caused by vibration and spread it out over a longer segment of the wire leading to reduced likelihood of failure. The standard kinds of wiring and attachment used in stationary appliances clearly wont stand up to road bumps and especially not to the constant vibration of a single cylinder motorcycle. over time. Nigel