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  #1  
Old 10th October 2018
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Default Anyone replaced a wiring harness?

Thinking about replacing my 30 year old wiring harness. How hard is it? Who makes a good replacement for a 1988?
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with the rise in prices, i doubt you can make your own but probably 5 years ago, i made my own cheaper than i could buy and with better wire. but for a new harness, you should be able to plug and play. one advantage of making it is you can run the wire where you want, mine is through frame like the original.
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When i did Mike's bike we got a good quality used one (low miles been sitting for a while) and added and subtracted to that one before installing on the bike. you'll need to remove oil bag and other stuff in the way..
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You might want to use a 1994-1995 (maybe thru 1997) main harness - 1994 was the first year they used integrated grounds in the harness - This helps minimize the flaky electronics of earlier models where there were 8-10 local ground points for the devices... From 1998-later the wiring harness will be made for the nosecone ignition (if that is something you want -or- not)...

I'm not sure what all you might need to extend or shorten to make the new harness fit the locations - not much I would expect...

Just make sure you check the harness for the continuity of each wire BEFORE YOU INSTALL IT ON THE BIKE... Fix EVERY issue you find...

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Old 11th October 2018
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I'm using dynatek ignition. And right now I'm battling one failure after another. My starter circuit is gone, my headlight just went out. I'm tired of wiring up workarounds. The insulation is getting brittle on the original 88 harness
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J&P Cycle sells complete wiring harnesses and I'm sure Dennis Kirk does too, complete with the proper ends and terminals. If this is what you are wanting to do.
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So if I get a new harness. Do I have to assemble the connector in the headlight bucket?
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Good luck trying to find a complete harness. Simplify the installation and do it the easy way with a MotoGadget module: https://revivalcycles.com/products/m...nit-controller

Instructions: https://bikebrewers.com/motogadget-m-unit-wiring/
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Quote:
Originally Posted by jharback View Post
Good luck trying to find a complete harness. Simplify the installation and do it the easy way with a MotoGadget module: https://revivalcycles.com/products/m...nit-controller

Instructions: https://bikebrewers.com/motogadget-m-unit-wiring/
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Quote:
Originally Posted by WI_duker View Post
So if I get a new harness. Do I have to assemble the connector in the headlight bucket?
I really couldn't tell you. Sometimes they come with the Terminals already on and sometimes you have to assemble them either partially or completely. I've replaced the harness on a '79 from the headlight to the circuit breakers and had to get a new headlight term block and wire that myself. In '96 a friend and I got a Novella harness for a Wideglide he was building and we still had to run homebuilt smaller harnesses to complete it. If you can track down a used harness in good shape that would probably work great. You WILL need good wiring tools (crimpers, strippers, the little terminal picks, etc.)
If you do it from scratch, keep your original harness in one piece to use as a guide, noting where the connectors go and how long the wires are for each system. Sticking to the factory color codes and wire guage is the hardest part.
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