Safety Wiring Your Bike
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Thread: Safety Wiring Your Bike

  1. #1
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    Exclamation Safety Wiring Your Bike

    To race on any track you will need to make sure you bike has been properly safety wired. Safety wiring prevents bolts and nuts from working their way loose compromising yours and other riders safety on the track. Proper safety wiring is a vital part of the technical inspection you will need to pass in order to get on the track.

    Below are some photos along with descriptions of the safety wiring as well.
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  3. #2
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    Caliper Bolts
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  4. #3
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    My toy !
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  6. #4
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    For the pinch bolts on this bike, safety wire clips which makes it easier to remove and install when making tire changes.
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  7. #5
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    Yea I stuck the thread......best thread I've seen in months !!!

    Artwork...
    Brian # 30


    KTM 450 SMR

    "Everyday is a good day" Just some days are better than others

  8. #6
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    here's the wasserpumper bolts done on the 06 450smr



    and the aft caliper pad retaining pins, (so they don't get lost!)

    06 625smc = sold
    06 450smr #927 = sold
    2010 gasgas txt250 pro
    2010 H-D XR1200 with V&H race kit

  9. #7
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    safety wiring is a PIA. Harborfrieght had 10 packs of 1/16th bolts for 1.00, I went through more then 30 bits doing my daytona. that was with a drill press. When I do my 510 i think im going to try and find a better quality bit.
    08 husky 510
    07 daytona 675
    04 fiddy

  10. #8
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    Quote Originally Posted by chimmy View Post
    better quality bit.
    you called it
    XRR

    When I say WWJD, I mean OTHER than buy his wife breast implants and a lexus, own firearms, and vote republican.

  11. #9
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    ive had good luck using ridgid drill bits

  12. #10
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    here's the rear rotor mounting bolts safetied in pairs.





    06 625smc = sold
    06 450smr #927 = sold
    2010 gasgas txt250 pro
    2010 H-D XR1200 with V&H race kit

  13. #11
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    those pro bolt Ti?
    look very nice.

  14. #12
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    Quote Originally Posted by MXRider View Post
    those pro bolt Ti?
    look very nice.
    from racebolts.com, they come pre-drilled, and ti !!!
    06 625smc = sold
    06 450smr #927 = sold
    2010 gasgas txt250 pro
    2010 H-D XR1200 with V&H race kit

  15. #13
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    I had a bunch of those on my 600RR race bike that I got from tastynuts.
    they look identical, nice stuff

  16. #14
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    hey, T-funk, do your safeties look like this?

    06 625smc = sold
    06 450smr #927 = sold
    2010 gasgas txt250 pro
    2010 H-D XR1200 with V&H race kit

  17. #15
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    Yup!!! Just like that only the pigtails are on the bottom and not the top..... but just the same.

  18. #16
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    Quote Originally Posted by Tfunk View Post
    Yup!!! Just like that only the pigtails are on the bottom and not the top..... but just the same.
    excellent!
    06 625smc = sold
    06 450smr #927 = sold
    2010 gasgas txt250 pro
    2010 H-D XR1200 with V&H race kit

  19. #17
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    Nicely done
    Its all about the Kustom!
    www.magiksc.com
    10 YZ 450F
    08 SM 450R- Building it my way
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  20. #18
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    Uh hey Heffe......Kimiko says that thing is DUUURTY.....give it a bath please...

  21. #19
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    Does anyone have a picture of Radial Brake on a shock safety wire?
    http://www.myspace.com/aurorasnowband

    05 Husaberg FS650E
    02 YZ250
    Trackday Counter: 8 / Crash Counter: 2

  22. #20
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    Well done - Looks like an aircraft...

  23. #21
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    Quote Originally Posted by hey Johnny Park View Post
    Does anyone have a picture of Radial Brake on a shock safety wire?
    hi, why dont you use loctite on the bolts?

  24. #22
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    Tracks require them to be safety wired but Ive found some pics already

    Oh here check this out

    http://www.youtube.com/watch?v=oOEbMsi-2QU
    http://www.myspace.com/aurorasnowband

    05 Husaberg FS650E
    02 YZ250
    Trackday Counter: 8 / Crash Counter: 2

  25. #23
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    front caliper on the 06 450 smr, i run the safety wire thru some clear tubing to keep the wire from chafing on the caliper.





    06 625smc = sold
    06 450smr #927 = sold
    2010 gasgas txt250 pro
    2010 H-D XR1200 with V&H race kit

  26. #24
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    Quote Originally Posted by hey Johnny Park View Post
    Tracks require them to be safety wired but Ive found some pics already

    Oh here check this out

    http://www.youtube.com/watch?v=oOEbMsi-2QU
    ohh, okey, i didnt know that

  27. #25
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    Quote Originally Posted by hey Johnny Park View Post
    Tracks require them to be safety wired but Ive found some pics already

    Oh here check this out

    http://www.youtube.com/watch?v=oOEbMsi-2QU
    As a retired 25 year aircraft mechanic, I must say..... Don't safety wire your bike like this. It looked as though he wasn't really trying to keep the wire tight and heres a little tip.... The industry standard is 24 twists per inch. And remember to use SS wire.... And apogee Johnny if that was you in the vid.... But you are not doing it right...

  28. #26
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    Hi,

    Would it be possible to get the pictures back in the post?

  29. #27
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    Quote Originally Posted by Judaslefourbe View Post
    Hi,

    Would it be possible to get the pictures back in the post?
    +1
    2007 KTM 950 SM-R
    2006 KTM 450 SMR Thanks to Modern Garage and Starr Cycle!
    1999 KTM 300MXC -Woods Weapon
    ***The most important concept of science isn't memorizing facts, it's observation of phenomena.***

  30. #28
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    Quote Originally Posted by Brazilsupermoto View Post
    To race on any track you will need to make sure you bike has been properly safety wired. Safety wiring prevents bolts and nuts from working their way loose compromising yours and other riders safety on the track. Proper safety wiring is a vital part of the technical inspection you will need to pass in order to get on the track.

    Below are some photos along with descriptions of the safety wiring as well.
    Make a jig for this. It will make the job a lot easier. Get a small piece of 2x2 of 2x4 and drill a hole on the end big enough to put the bolt in. That's it, the bolt will stay square and it's a lot easier to hold onto the wood than the bolt

  31. #29
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    Nice use for the barry clip. Great idea. I'm using it!

  32. #30
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    here's a repost of the waterpump bolts safetied on the 450smr.


    yes, the hose clamp is safetied also.

    and, shift lever and countershaft sprocket.



    and rear rotor bolts safetied in pairs.


    06 625smc = sold
    06 450smr #927 = sold
    2010 gasgas txt250 pro
    2010 H-D XR1200 with V&H race kit

  33. #31
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    Great Job ! This is my front caliper...

  34. #32
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    Quote Originally Posted by Brazilsupermoto View Post
    Great Job ! This is my front caliper...
    i see that you have witness marks on your rotor-bolts, very nice!
    06 625smc = sold
    06 450smr #927 = sold
    2010 gasgas txt250 pro
    2010 H-D XR1200 with V&H race kit

  35. #33
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    here's the front caliper safety, (ran it thru a piece of hose to keep it from chafing on the caliper).




    the safety on the radiator cap.

    06 625smc = sold
    06 450smr #927 = sold
    2010 gasgas txt250 pro
    2010 H-D XR1200 with V&H race kit

  36. #34
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    nice caliper ! loocks strong - what is that ? a tire blanket ?!

  37. #35
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    here is some drain plug examples


  38. #36
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    f*** me! never u had to this, makes sense tho

  39. #37
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    Excellent thread! I'll definitely be doing the vibration-prone fasteners on my CCM...

  40. #38
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    Quote Originally Posted by chimmy View Post
    safety wiring is a PIA. Harborfrieght had 10 packs of 1/16th bolts for 1.00, I went through more then 30 bits doing my daytona. that was with a drill press. When I do my 510 i think im going to try and find a better quality bit.
    Try using a good cutting fluid, and maybe check your speed on the drill press. It might give you better results.

  41. #39
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    Here is a few tips on drilling bolts --

    Use Solid Carbide or Cobalt drill bits-- they cost more but will
    cut threw steel like butter--
    Many Allen type bolts are Hardened so regular HST (high speed steel )
    bits wont work at all --

    Use STUB-Stubby length drill bits (about 2 inches long )
    wont flex -
    Always is drilling -cutting fluid when drilling -it helps alot
    (above can be purchased from machine shop supply) -

    Use a Drill press vise-- it is a very low vice -about 2 inches tall -
    bolts to drill press table and cost about $15 or so-- ebay-

    Safety wire pliers are a Great tool -- they twist the wire automatically - neatly
    and are very easy to use--
    Always use Real SS safety wire - roll cost $10 -
    the above tools can be purchased at aircraft supply houses
    like Aircraft Spruce--
    while looking at aircraft tools check out -- Clecos --
    they are a Temporary type of rivet that is spring loaded
    and can be easily removed and used over and over -
    they also make small clamps- both can be used in hundreds of ways-

    You Must purchase the Cleco pliers -regular pliers wont work-

    Have Fun--Jay--

  42. #40
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    Does anyone have any pictures or tips on how to safety wire a master link on a chain? I've done a few searches and can't seem to find anything specifically for the master link.
    2016 KTM 500 EXC//2007 CRF100 Mini Road Racer/beater/funbike//2015 Yamaha FZ07

  43. #41
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    The only way I have seen is to remove the master link -
    Add one regular link and use a your chain breaker to Re Rivet the chain
    together--

    Its not hard to do --The secret is to not remove the pins completely
    you want about 2mm of the pin still sticking to the inside of the link--

    When done corectly the chain will stay together where the pins are
    pushed --you will twist the chain slightly and it will come apart
    and snap back together Easily because the 2mm of pin
    will go into the hole of the new link --

    To practice get a old piece of chain and count the turns it takes the
    chain breaker to push the pin to the correct position--Jay--

  44. #42
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    great thread!

    There are lots of drilling jigs on the market too. I havent decided if i want to buy one yet but for $20-$30 they would save a lot of headaches.



    Something like this is only $8
    http://www.motosport.com/dirtbike/pr...JIG/?id=115391

  45. #43
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    Here goes guys - At work...







  46. #44
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    Safety first Oil Plug




  47. #45
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    Front Caliper


  48. #46
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    Great thread but what are the rules as to what you need to wire.

    I would think there is a rule like any bolt or threaded device in blind hole etc,

  49. #47
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    Default Required safety wire...

    Quote Originally Posted by artracing View Post
    Great thread but what are the rules as to what you need to wire.

    I would think there is a rule like any bolt or threaded device in blind hole etc,
    It depends on the racing organizations, track rules, etc...here in Texas the roadracing organization CMRA has what must be done in the rule book. In general anything that can come loose and kill you, or somebody else is a good idea...in general.

    If your just doing trackdays, its not usually a requirement, but its not a bad idea anyway. Competion, is another animal, its almost always a requirement to get on the track.

    Any questions just get ahold of the racing organization and check with them.
    2009 DL1000, Gsxr750 2002, Dr650 2004

    Any fool can make a rule, and any fool will mind it.
    Henry David Thoreau

  50. #48
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    safety wireing of bike is so important,if your bike wires are so loss and doesn't work properly you have to face a problem.So we have to want a bike maintenance is time to time.

  51. #49
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    Quote Originally Posted by spyindia View Post
    safety wireing of bike is so important,if your bike wires are so loss and doesn't work properly you have to face a problem.So we have to want a bike maintenance is time to time.
    Did you have a stroke just now?

  52. #50
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    I didn't see anyone mention tab washers? These are for situations where a fastener refuses to be drilled. Say a 12.9 or ARP bolt or just no drill available at the time.


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