Rebuilding the whole wiring loom

[alexandervf]

Good evening all,

A few months back i decided to rebuilt the whole loom of my bike.
Well, it was a very painful procedure but the results are rewarding.
Yesterday, after 7 months of trial and error i finally fired her up again.There was a big smile on my face knowing that this was an effort that i could not afford to fail.
Minor mistakes, they where dealt within one day though the haynes manual kept confusing me.
Anyway all is well and looking forward to ride her again soon...

Bellow i added some photos of my "journey"
Note that all the new wiring is silver plated teflon wire.A high grade , also very expensive wire.

A pic of some of the wiring i bought and used....


Connectors and terminals....








Something you should know if you 're about to mess with teflon coated wires, the are NOT stripped with the usual method or tools, you will be needing a proper tool or something like this i made...



The beginning.....



Switches in the process.....






Smaller loom for the clocks...(Note that due to the fact that not all connectors can be found (like the ones that hold the bulbs of the clocks i just did not mess with them...



L/H switch gear...




Something i also did a few months back, was installing led tape in the clocks,.....







.....and the led tail light i have shown you before...







The Reg/REc would not go away with this that easy, i added a thermall switch so that the fan comes on when the heat sink reaches about 40 degrees celcius you can see the switch bolted on the heat sink.....











New spark plug wires and caps.....


And the stator....finally. I unwound the stator cleand the core and after 4 failing attempts...I did it
The core....


1st fail ( "Coating of the core" with teflon tape)


2nd fail ("Coating of the core" with electrical tape)


and a few attempts that i did not take pics.

After several failing attempts i found out that a special kind of plastic paper is what you need to cover the core of your stator which i held in place with epoxy glue.
The final stage would be submerging the whole stator in a special resin that can withstand oil and engine heat.






And this is the outcome...


And a few shots of the CDI unit....




What you saw in the pics was not even half of the job. My hands still hurt from winding the stator.
The whole process was very interesting though the risk of damaging seriously the engine was high.
Above all I very much enjoyed it //i1139

[cbr400rrn]

Very impressive, i take my hat off to you

[alexandervf]

Thanks! That's very kind of you

[CRM]

Wow that's some attention to detail.
I will be the first to ask - why make the loom and not just buy another genuine part ?

[squirrel_hunter]

Impressive.

[VFRkieran]

Wow that's some attention to detail.
I will be the first to ask - why make the loom and not just buy another genuine part ?

Was going to ask the same question, can still get brand new looms from Honda for around £90 if i remember correctly! You have done a brilliant job on that though.

[Neosophist]

Wow that's some attention to detail.
I will be the first to ask - why make the loom and not just buy another genuine part ?

Was going to ask the same question, can still get brand new looms from Honda for around £90 if i remember correctly! You have done a brilliant job on that though.

184 quid plus vat!

Nice job.

Interesting to see why you moved the reg/rec.. in the original position there is some wind and the subframe metal acts as a heatsink.. they are supposed to run quite hot so the fan might be a bit of overkill?

[alexandervf]

Thanks once more for your kind words.
There are two answers to your question.
The first says that it's another thing to built it yourself with your choice of materials and another to just buy it with what honda chose for you in the mid 80's or 90's,after all electrics is very important part for the engines performance. I know i could have bought it from David silver and have my bike running in no time but i did not want it that way.
The second says that i wanted a bit better quality of wiring and connectors.
Now, to answer Neos question. I know that the original position had only one advantage,that there is some wind in there. The subframe there too acts as heatsink. If you watch closely at the metal parts that extend from the metal base i have glued on 2 black ruber parts to the base to stop heat coming from the subframe.The most important reason for moving it though had nothing to do with heat or funneling of the air.
It had to do clearly with the fact that i replaced the reg /rec with an R6 one. The heatsink of this reg/rec is at least double the size of what honda sells as an original part which has no heatsink.
So,this reg/rec and the previous one had very large heatsink. The fins of the heat sinks cracked the left panel of my tail.
I did not want this to happen to the new ones i bought from David S.

[JZH]

Very impressive work!

Could you please mention your sources? I don't know of anywhere to get teflon-insulated wire in multiple colors, for example. (Vehicle Wiring Products in the UK has an amazing selection of wire--even with tracers--but not teflon, AFAIK.) Or the infamous red connector housing for the main fuse/starter solenoid. Or even the Furukawa terminals for the PGM-FI connectors (are they the .090 ones from Eastern Beaver or MWS?)...

However, I'm afraid your reg/rec solution may not be the final one... That's because your "new" reg/rec is still an old shunt-type unit, not one of the newer MOSFET ones Honda switched to for later models (and which are used on the Yamaha R1, among others), nor is it a series-type reg/rec, like my CompuFire. Your temperature-controlled fan will help you fight the reg/rec-destroying heat, but a better solution would be to not produce excess heat in the first place!

Ciao,

JZH
So.Cal., USA/Hong Kong SAR, PRC
http://www.vsource.org

[alexandervf]

I bought all the wires from http://www.bulkwire.com Very fast!!!. Note that they do not carry color combinations.
If you want to replicate the honda wiring you will have to use colored heat shrink tubbing. For example, red teflon wire of 14awg with a small piece of white heat shrink tubbing.Then you have Red wire with white strip and so on.
Ahhh, yes you noticed, the red connector. Well i was VERY lucky with this one. I do not remember right now my source for that but i will search my emails and let you know.These guys where very helpful but they also told me that these connectors are about to go "extinct".None caries them or sels them any more.I will add a link for you here though and you can ask them.
The Furukawa terminals they are indeed the .090 ones eastern beaver sells,very helpful and fast too.
Yes i know about the reg/rec i just did not know that there was a mosfet one at that time.
" a better solution would be to not produce excess heat in the first place!"
Very good thinking! Can you please also give me a code of a mosfet reg/rec like the one that is typed on my reg,so that iknow which one to buy when this ones crashes?
Best regards