7-way umbilical replacement

[Silver Britches]

The 7-way cable on my Bullet 243BHS is way too long. I bungeed it (should've zip-tied it, I know) to the frame to take some of the slack out so it wouldn't drag going down the road. Bungee came off and I ended up dragging it 20 miles or so. The outer PVC was worn through, as was the sheathing on the wire inside. Bare copper. I wrapped it in electrical tape as best I could and re-bungeed and kept going. That was a couple of months ago.

Now, one of my tail lights is completely out - no brake or turn signal. Bulb is fine (trailer is a 2016). Seems like it has to be either a short or the 7-way. Given what happened, I'm inclined to believe it's the 7-way.

Has anyone ever replaced it? I would think it's just a matter of opening the junction box and tying color to color.

[Desert185]

Or you could cut and splice it. It would be as short as you need, too.

[chuckster57]

I wouldn't cut/splice. There are 7 wires and even staggering the splices would make for an ugly repair. New umbilical cords are cheap, and you can cut the end to the length you need.

Yeah just match colors, just make sure you NOT plugged into shore power, and disconnect the battery(s).

[Desert185]

I wouldn't cut and splice, either, but its an option others might pursue. It wouldn't be too ugly looking like a freshly fed python.

[Mike484]

Mine too was way too long, it fell between the WD bars and the tongue and got pinched in between, cutting some of the wires. I just cut it the rest of the way and put a new plug on the end, now it is no longer too long and I dont have to worry about it getting pinched again.

[drdarrin]

If you had gotten to it sooner, I'd be in the splice it camp. Now that moisture has had time to do its thing, I'd replace now too.


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[B-O-B'03]

Howdy Silver Britches,

The same thing happened to mine and I did not notice until we stopped, after 200 miles, for gas.

I came out, after paying for the gas and noticed the cord looked a little close to the ground... it was and had worn almost completely through (explains the drop in braking performance ).

Fortunately I had wire nuts and tape in my tool bag, so I was able to repair it.

I ordered a new one from amazon and had it in 2 days, they come in assorted lengths, I bought an 8 footer and cut it down a little.

Here is the link for it.

-Brian