Topic: Extending Wiring Harness

[MIKE029]

howdy folks....starting a restore project on a '75 cb550. probably gonna go with a cafe/track bike approach. many questions to follow but right off i'm wondering if anyone has ever re-routed/extended the wiring harness on this type honda. my initial plan is to re-locate the entire cluster of electronics ( fuse holder,voltage reg.,flasher ect.) up under a new cafe seat/fender.......any advice out there ??    thanks.mike029

[Alan F.]

I think it's pretty common, just use the correct size wire. Then solder your connections and use heat-shrinkable tubing to insulate every connection, you should be fine.
-Alan

[Don R]

Just remember to use some sort of plug in where you may need to take things apart later. Drag racers use the weatherpack GM type a lot. There is a supplier of stock type honda connectors listed on here somewhere too.

[bucky katt]

Mike, i felt the need to pop in and tell you, i LOVE your avatar "my name is EYEgore" marty feldman cracked me up.

[Spruce]

.......any advice out there ??

I recently saw a neighbor, Phil, working on a wiring harness that had been extended with various wire colors that were sometimes "close enough" and sometimes not so close.  Phil was salvaging wires off a parts bike to fix the runner's wires in 100% correct colors.

If you have a parts bike in a suitably advanced state of decrepitude, it might be a good trade.  I doubt that I'd hack into a parts bike with a near-complete wiring harness.

[mystic_1]

eBay a stock harness for your bike and salvage what you need from it.

I've extended and rerouted my harness as necessary, just do it right with correct wire and connectors, and it'll be fine.

Be mindful of adding TOO much new wire, each foot adds resistance.  Sometimes it's better to whip up a separate sub-harness for things and just cap off the unused stock leads.

mystic_1