Topic: Tips for restoring factory wiring. 550k1

[turin39789]

My bike has a rat's nest of wiring, it was starting and running and I had the running lights, brake and headlight working.  No tail lights and all the wires are half connected and hanging outside of the headlight.   

My starter has started to stick, and my speedo was going out so I bought a replacement(blue faces vs my old green ones though?)   and when wiring it up I seem to have lost the headlights and starting function.

Any tips on sorting the wiring out?  I'm planning on pulling the tank, taking the headlight off and comparing the wiring diagram to my wiring and just putting the like colors together.  On the junctions where 4 bullets come together, does it matter where the bullets come in or do these junctions link all 4 wires?  Should I get a specific contact cleaner and spray everything, and then finish with Dilectric? 

I imagine it's going to be frustrating and the wires will go places that make no sense to me.  The bike had a windjammer fairing on it before and I think some of the wires might have been cut and replaced, but I think the harness is essentially whole.  I just hope I can get it back together, hopefully improved and running again.

[Bob Wessner]

Should I get a specific contact cleaner and spray everything, and then finish with Dilectric?

You should be able to find electrical cleaner at just about any auto parts/supply place. I went through my entire harness, connector-by-connector three years ago. I took a Q-tip and pulled off most of the cotton (if you don't it won't fit). Dipped what was left in cleaner and worked around inside the female side. Then wiped the male side. Put a dab of dielectric grease on the male side and shoved them together. If they are badly corroded, you may want to consider some fine rolled-up crocus cloth as a first step. One of the best couple of hours I've invested. Lots of things electrical started working again after sitting for 22 years. It was a stock harness though.

[Short Round]

I cleaned all my connections with a regular spray can of electrical cleaner, just blasted all the connections inside and out, let them dry and fit them back.  As for sorting out your wiring problem I would refer to the harness diagram in the back of the repair manual.  If you don't know how to read one  well get someone who does.  They are pretty simple.  As you go along just post questions here.....waint 10min and check back.  Hope this helps............Chris

[turin39789]

Got a few pictures of my mess, most of which is hanging outside the bucket when it's on.  Just got the bike running with a new ignition switch though, so I'm off for a quick ride!  Lost my neutral light while fiddling with the wires though