Making a wiring loom

[mr jamez]

Well, after a lot of fannying about and wasting money I am fed up with buying looms from breakers/ebay only to have them fall apart due to corrosion. I made up a loom to get the bike going and it worked fine, so am going to go ahead and make the whole thing.

I have a loom here from a 2003 NSR which I will use for parts of the new one, It is covered in a sticky substance which I guess helps prevent corrosion etc, anybody know what it is?

Also I need a load of pre-insulated terminals (the type that stinkwheel recommends) and the crimping tool for them, but cannot find them anywhere! anybody know of a good place? I am basicaly going to get rid of most of the connector blocks and use the bullet terminals instead.

Oh and need a shit load of different coloured cable. Any tips on how to make a decent wiring loom that will not fall apart will be appreciated

Ta.

[Guest]

Everything you might need is available here ....

https://www.vehicle-wiring-products.co.uk/VWPweb2000/homepage/home.html

or probably Halfords.

for cable I'd go down the local car scrappers and pinch a few yards of wiring loom off a wrecker.


the existing loom is probably wrapped in self-amalgam tape which sticks to itself and helps keep moisture out - the same sort of stuff they put round satellite LNB connectors.

[mr jamez]

Excellent

[Stew]

I got a set from maplins electronics, they sell loads of spare bullet and spade connectors too.
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"Unlike public school you don't need to have your arse up and your head down to go a long way...."

[stinkwheel]

Check out this link:

https://www.btinternet.com/~jhpart/bkwirec.htm

Tells you everything you need to know, and a lot of stuff you don't.

Top Tips having rewired two bikes from scratch:

Draw colour wiring diagrams on MS paint. Don't be afraid to modify it as you go along but remember to alter the diagram too. When finished, laminate a printout and keep it for future reference.

A lot of the wiring on Japanese bikes is redundant, just because the manufacturer has put it there, doesn't mean you have to.

Treat the wiring as several 'systems' and do them individually. Helps avoid confusion by breaking it down into manageable bits. I usually wire up the ignition and charging system first and make sure this works, then do the lighting and accessories. Last time I did them entirely seperatley with two 'bundles' of wires maing up the main loom. This means I can undo all the accessory and lighting wiring by disconnecting a snap connector, thus putting the bike in 'safe' mode with the minimum necessary to keep the engine running and limp home should a fault develop.
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“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.

[stinkwheel]

Oh yeah. I recommend the non-insulated bullet connectors with the seperate insulation sleeve rather than the pre-insulated ones. Fit with a dab of copper grease for maximum corrosion resistance

Vehicle wiring products as linked by guest is the place to go. You can get a connector kit with a crimping tool and a selection of terminals from there. Go for the most expensive crimping tool you can justify buying.
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.

[Guest]

[mr jamez]

Sounds like a good idea Will finaly have a loom that I will be able to make sense of.

I have the ignition and charging circuits done in MS paint, so will do the rest before I make them. I think this might actualy work, thanks again.

[ZRX61]

Ya gonna need a sheet of plywood....
Ya lay out the original on the plywood & use loads of small nails to temp hold everything in place. Then take a sharpie (the pen, not the dog) & mark what/where everytyhing is on the plywood. Remove the original harness & then use the nails etc to lay out the new one. Piece of piss

[bish777]

i find ignition sealer spray is great for waterproofing looms once youve made it up, make sure you cover up the connectors tho lol

Ive completely rewired the ignition on my 1100 after finding most of the wiring was rotten!
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GSXR1100J