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I fried some wires last week (bad connection I suppose) and decided to go ahead and make a new harness myself. worked on it yesterday from about 6pm until 3am, then had nightmares about connecting the wrong wires until I woke up for work. Everything is coming along well, but slowly, and I would say that for my first time using a solder gun I am pretty handy with it. I thought I would post a pic of the process, I kinda went back and forth between the manual and the old wiring harness in front of me, a few small things were done differently but all in all it was pretty easy to follow. I only wish I had used a bigger workbench.

Here is what the bike looks like so far with most of the stuff off for cleaning. I put drag bars on and am trying to get all the connections/cables/etc. to fit cleanly. It still needs lots of love, but I'm proud of it so far.

Post edited by: 77Davo650, at: 2006/06/13 11:03

Looks nice and clean. Have you found that you were able to simplify or reduce the total number of wires used? Did you just lay the old one out and copy the length or are you going back and forth to your bike to check the fit?

I could have reduced the amount of wires significantly, but I then decided I wanted to have the option of installing all the lights and bells and whistles if I wanted, plus I really wanted to be able to reproduce the entire harness this time around, so I'm doing it all. I am not going back and forth between the bike to check the fit, I laid out the existing harness and measured the lengths and then added where I thought I would need extra. I have a lot of the new harness taped down and marked on my work table so I am trying to keep it all organized until I get ready to install it. I did notice that a few of the wires were different colors or that they were connected a bit differently than the clymer manual diagram would lead me to believe, so having both really helped. I'd like to be able to draw a more user friendly version of the wiring diagram, maybe I'll get around to it sometime.

So when you're done that one, I'll take one too.

Hows it coming along?

Im in the middle of a rewire myself. Im too cheap to start from scratch but leaning that way more and more every time I think about it. Friday is fun money payday so I might be heading to the Rat Shack that night.

I'd like to redo my harness using some of the teflon insulated wire I've seen in some boutique guitar amps. That stuff's expensive, though...

What are you using for connectors?

I actually finished the harness early last week, but I am waiting for some turn signals to get in before I get to wiring it all back up. The harness itself wasn't bad at all. I also need to get in and clean all of the electrical parts I am re-using. I'd like to get the bike put back together and start it again this weekend hopefully. The engine kill switch on the right control wasn't working so I also need to rig up some switches this week. I'll get some pics up later.

Oh, for connections I'm soldering all I can. It's the only way to be sure . Up at the handlebars I might use bullet connectors just in case I want to change bars and not have to cut and re-solder the wires again.

Post edited by: 77Davo650, at: 2006/06/19 13:21