Wiriing harness back together

[Rickytic]

During my restoration process of my CL77, I completely dismantled the bike down to the frame which included taking the wiring harness off the bike and completely rebuilding the harness with new outside sheathing to make it look new. I had to take a lot of bullet ends off the wires, replace some of the wiring and then re-solder the bullets, even dismantled the high/low beam switch, horn button re-wired, then re sheathed. To make a long story short, I put the wire harness back on yesterday, and this morning hooked up the battery.......To my amazement, it all worked without a hitch......I will say that the most challenging part was the high/low bean switch and horn button assembly, like working on a watch...I learned a lot about working on the switch and if you are contemplating undertaking this type of project, it is simple but teadious and I certainly am willing to share my experience.

Rickytic

[rzgkane]

During my restoration process of my CL77, I completely dismantled the bike down to the frame which included taking the wiring harness off the bike and completely rebuilding the harness with new outside sheathing to make it look new. I had to take a lot of bullet ends off the wires, replace some of the wiring and then re-solder the bullets, even dismantled the high/low beam switch, horn button re-wired, then re sheathed. To make a long story short, I put the wire harness back on yesterday, and this morning hooked up the battery.......To my amazement, it all worked without a hitch......I will say that the most challenging part was the high/low bean switch and horn button assembly, like working on a watch...I learned a lot about working on the switch and if you are contemplating undertaking this type of project, it is simple but teadious and I certainly am willing to share my experience.

Rickytic

I concur. That high/low switch was begging for a small Japanese man with tiny fingers to put it back together. I suggest to anyone working on those switches that you do so with a soft cloth below you while you sit on the floor. That's so when the detent ball and spring fly away for the umpteenth time, you don't lose them.

[Rickytic]

rzgkane,

You are so right. When I started with the switches, I had a choice to un-solder the pin barrels at the headlight side of the wiring or un-solder the switch wires...DUH!! I picked the switch side. I took the switch apart, un-soldered the wires, cut the ends of the wires so I could restrip and re-solder after replacing the sheathing with new. I build custom fishing rods, so working with this project was not too bad, used a few tools that I use on fishing rods and the process went pretty smooth.....But, as it seems, you already know, the little spring, ball bearing, and other parts can sure run away and hide from you at times. Actually had to walk away from it a couple of times to collect my thought process as to how everything should have been put back together, and how to make it easier to do it. All is well and all works..and the first time I tried it.

[rzgkane]

rzgkane,

Actually had to walk away from it a couple of times to collect my thought process as to how everything should have been put back together, and how to make it easier to do it.

That sounds very familiar. :-) About two hours of cursing is par for the course.

[ahenthus]

Rickytic,
My wiring harness is in terrible shape but I think it's complete. My plan is to build a completely new harness with all the correct wires and fittings. I know where to get a generic kit for the sheathing and associated hardware except for the rubber boots. Is there a certain supplier that stands out? What size are the silver plastic sheaths and are the rubber items available? Mine seem to have shrunk a little due to heat and age maybe. Thanks so much for your offer to help.
Claude

During my restoration process of my CL77, I completely dismantled the bike down to the frame which included taking the wiring harness off the bike and completely rebuilding the harness with new outside sheathing to make it look new. I had to take a lot of bullet ends off the wires, replace some of the wiring and then re-solder the bullets, even dismantled the high/low beam switch, horn button re-wired, then re sheathed. To make a long story short, I put the wire harness back on yesterday, and this morning hooked up the battery.......To my amazement, it all worked without a hitch......I will say that the most challenging part was the high/low bean switch and horn button assembly, like working on a watch...I learned a lot about working on the switch and if you are contemplating undertaking this type of project, it is simple but teadious and I certainly am willing to share my experience.

Rickytic

[Rickytic]

Hi Claude the following is where I got my sheathing:http://vintageconnections.com/
They offer 3 different sizes of sheathing, I used the largest two sizes. Got about 10 ft of each. I used the original bullet connections that came with my harness. They unsolder fairly easy, and then resolder to the new wires without much problem. Vintageconnections carry both the male and female connections and offer a kit that comes with the crimpers etc. When you get a chance, try the website and see what you think. They also have the silver tape that is used near the junction where wires join together. There might be other sites that offer this stuff, but I couldn't find any. If you use their connections, they are crimped onto the wires not soldered as the originals are, but really look nice. I am not sure what rubber boots you are talking about, if it's the boots that cover the coil terminals, I can't help you at this time as I am still looking for those or some close to the originals. So far they have alluded me..

You might want to measure/tag/and take a bunch of close up pictures before you start. Additionally, if you can, use the original wires, unsolder the bullet tips, put the new sheathing on, retape the joints, resolder the tips, and call it a day.

Hope this has been of some help to you and by the way, your local auto shop (Kragen/O'Reilly etc) will probably have the color and guage wire you will need for the project.

Rickytic

[ahenthus]

Thanks Rickytic, I knew about Vintage Connections and will probably buy the sheathing from them. I appreciate the tips.
Claude