OK, so I've downloaded the loom diagram from the site and I'm gonna be atempting to wire the bike up over the next few weeks, but what I'm looking to know is where to get all of the loom connector blocks eg the ones for the CDI etc Do I need to get a chopped one from another loom, or can these be bought new?

Also, the bike will be running total loss, so will I still need a reg/rec? Silly question, I know, but I'm not sure.

You can get most connectors that you need here http://www.vehicle-wiring-products.eu/V ... mepage.php although the CDI ones might be honda specific.

No need for the reg/rec on total loss mate

Have a look at this guy:

http://www.ebay.co.uk/itm/HONDA-CBR400- ... 53e8e9fbc9

He does a lot of motorcycle connectors. Also, I find this shop quite useful for a lot of obscure bits and pieces:

http://www.vehicle-wiring-products.eu/V ... mepage.php

EDIT: Looks like DM beat me to it. Oh, I just remembered, have a look here as well:

http://www.dataspares.com/connectors_home.html

I e-mailed them about a starter relay connector a while back and got a reply saying they were discontinued, but that they had a second hand one knocking about I could have for the cost of postage.

Well, (Amorti this is also for you too because you asked....if you read this post)

Race loom or not it depends on whether you want to make it a good looking and quality job OR a cheap but nevertheless functional one.
In the second option i cannot say much because i never follow this path when it comes to repairing/restoring (If i have the money i will do it otherwise i will leave it as it is).

In the first option, be prepared to put some real cash on it.

FIRST: The wire.

I chose silver-plated Teflon wire (VERY expensive...I know it is not a rocket i just like a quality job ) i buy 2 25feet at a time (you don't have to buy everything in one go...at least i cant). I am buying it from: http://www.bulkwire.com
You will be needing from what i have measured until now 4 gauges : 12AWG, 14AWG, 18AWG and 20 AWG multiply it with the variety of colors you will be needing..... YES a lot of money and we just begun

SECOND : The Blocks.

In this case i also chose to replace the 17year old blocks with newer waterproof ones, like the ones that newer bikes use. I found a big variety at http://www.easternbeaver.com. I WILL NOT be replacing the fuse box because I found the connectors (Yes amorti i did )
http://easternbeaver.com/Main/Elec__Pro ... terms.html look at the botom of the page!!
Again, a lot of money. This time it is a number of expensive waterproof blocks with some extra connectors (Just in case ) All these blocks come with their connectors you just have to buy a few more.
I have not found ...yet the CDI block and the starter solenoid block.
I consider these to be near impossible to be found.
Nevertheless you can get the EXACT CDI connectors for the CDI block from RS electronics. Their part number is :
679-5741 and they are sold in packs of 100pcs.

THIRD : Bullet and other type of connectors.

A good place of sourcing them is : http://www.sgmotorsport.co.uk , http://www.easternbeaver.com and other on-line shops (cannot mention all) . Just buy them tin plated (They have better resistance properties to corrosion).


FOURTH : The final sleeving of the loom.

Electrical tape is out of the question to begin with This was a mid 80's practice when heat shrinkable tubes where used only by NASA.
Here http://cableorganizer.com/, here http://www.wirecare.com/ and a few other places you can find sleeving solutions.
And to complete the masterpiece....heat shrinkable boots like these : http://www.prowireusa.com/products.asp?dept=37

FIFTH : Tools

In my opinion, the only GOOD and EXPENSIVE tool you MUST have, is at least the crimping tool. Every other tool for this job either you already have it or they are not expensive.

I am already on the job and have not completed it, it will take me months to complete...I just cant wait to see the outcome, so i cannot answer questions you might have. (I mean i do not know more than you already know).
Hope this helps, this what i have found out until now.
If i have something new i will let you know And a last thing......PATIENCE
CHEERS

We have found polevolt to be good supplier for us. I opted for the econoseal connectors in an attempt to overengineer the bike out of any loose connection problems like the ones we had last year.

That was 100 quid in connectors alone!

alexandervf, as our loom is a race loom...can we get away with just two grades? Some high AWG for high load wiring and lower for the rest? Its already been far more expensive than I imagined it being like you say :)

dx4 wrote:.can we get away with just two grades?

Hmmm, don't know that. The wire that i'm using has good properties. You could for example use 18AWG wire for both 20AWG and 14AWG but i cannot be certain that your CDI will function properly.
CDI wires carry low voltage signals, cant say if the wire resistanse would be correct to drive CDI commands.
In short words,this might afect spark plug fireing.
Might afect elsewhere too but as i said above i have not finished yet to offer you any more help...(If you get what i mean...not the best english).

Just like to add that finishing sleeve (outer) to protect all wires etc. Vulca tape by 3M or Self-Fusion tape can be used (know this from my previous job at an International company where similar products like various cable harnesses were designed and build according to the often high tech industry compliances and specs including harnesses for automotive, aviation, military defense, semi-conductors (i.e. asml/philips/nxp).