Just got my motor back from CNW.

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I feel like a kid on Christmas morning.

I just got my MKIII motor back from CNW and it looks bloody fantastic.

I feel like a tool as I can't post pics because I don't have a photobucket account and I can't figure out how to post them here without a photobucket account :oops:

It's also really cold up here so I won't be able to start putting everything back together until mid March when things warm up enough for me to hit the garage :cry:
 
Who wants to give me a crash course in motorcycle wiring?

I'm startingf rom scratch, building a negative ground harness with no signals. I will need to dummy wire in some signals for inspection then I'm yanking them off.
 
I have a simple wiring diagram done in AutoCAD, I'll try to post it up. It has absolutely no spare wires beyond what the bike needs to run with electronic ignition and basic lighting.
 
grandpaul said:
I have a simple wiring diagram done in AutoCAD, I'll try to post it up. It has absolutely no spare wires beyond what the bike needs to run with electronic ignition and basic lighting.

Paul, that's fantastic. That's the only thing I'm kind of sweating over. Matt said I can call anytime for some tech help. I figure I can dummy wire the signals but I'm thinking I should keep a horn on there.

I'll start a build thread once I get my act together and it starts to warm up around here.

The main thing and first on the list is to remove excess powder coat from the tranny cradle and iso mount points. I've been putting off that job since last October when I got my frame powder coated.

I'll also take some pics and try to figure out how to post photos on here.

Also, when thing starts going back together I'll be asking a ton of questions as I have never put a bike back together before. Actually this was the first time I even took one apart.

Baptism by fire for sure but at least I did things right and get a proper engine and transmission rebuild.

Once I find that old Harley Shovel Head basket I'm looking for I'll try my hand with some motor work, but I didn't want to experiement on my Commando. My vsion is too great for this bike to do first-time engine work on.

I'd be completely lost if it wasn't for this wonderful forum and all of the highly knowledgable and generous folks on here.
 
Try it like this, but check out the "disregard wire color labels" note...
Just got my motor back from CNW.
 
You can also wire one or both of the tail light circuits through the light switch, but I don't like to.

Furthermore, you can wire the light switch to the "hot" side of the keyswitch so you can turn on your headlight without the key, but then you've got a possible battery drain if something goes wrong or you forget to turn it off.
 
Dang, WRONG FILE!!!

i'll get that negative ground drawing up later this evening, have to get dinner on the tabe for a ravenous 3-year-old...
 
Coco said:
Who wants to give me a crash course in motorcycle wiring?

building a negative ground harness with no signals.

There are some simple wiring diagrams to start from at Old Britt's. The negative ground ignition circuit is at the bottom, so scroll down.

http://www.oldbritts.com/simp_wd.html

I used thie resource to help me re-wire my '73. Of source, if you're building a Mk III with electric start then that has to be added in.
 
My 72 harness has 1 or 2 quirks with it like the tributary branching off before passing through the frame grommet instead of behind it like I'd planned. Also there are some tight spots where some of the wires could have been 1/2" longer so they weren't practically trying to pull themselves off their terminals. Although the following may be pretty basic it may help avoid some of these annoyances.

Are you using an old harness as a doner or are you starting with new wire or both? If you use an old harness you can use the coded wires for the same components as in the standard wiring diagram. If you are using a doner harness start by hanging it to the rafters and stripping all the tape off. A razor knife is handy.

Plan where all your components will be mounted. (I concentrated most my electronics at the battery box on my 72)

Plan where your junctions will go. Norton uses the headlight and under the tank as main junction spots so you can disconnect wiring when removing parts for repairs etc.

Bolt all electrical components in position (lights, switches, ignition stuff etc., everything) Tape the barrel (gang) connectors to the frame or where you will be using them. Think of the gang connectors as components like everything else as it's easy to forget them.

With all components fixed in their positions you can start stringing wires. A wiring harness resembles our spinal cord with the bulk of nerves traveling along the backbone. Tributaries branch off and they fork out to the different extremities. Run the long wires first. As you add wires, tape them together with a single wrap of tape when they get close enough to any other wires but leave the ends long. Velcro strips would work better than tape for this when building up the loom as you can more easily open it up and add a wire as you go and you can more easily slide the wires in the loom to remove any slack. As you progress you may find you may want to change how a wire is routed. Main tributaries should follow along frame rails or other components and remain as hidden as possible. By taking the shortest path you may find the wiring itself may hinder the removal of certain parts at a latter date. Before crimping or soldering the ends make sure the run of wire is a little long as you will loose a bit of length when you start taping it all up. You are better to have the wiring a little too long rather than too short where it would pull out from a connection because it barely reaches it. Before soldering or crimping use lots of tape or velcro strips on the harness every 3-4 inches and at branch off points keeping the bundle of wires super tight so the points where tributaries branch off and the wire lengths remain accurately positioned. When it's all tight and in place trim off long ends, crimp/solder and tape it up. It will be easier to remove the harness to tape it up.

I assume you would be using the stock switch clusters on the handle bars. They connect to the main junction block under the tank so you could wire dummy circuits from there to the signals using black wires just taped to the harness and strip them out later.
 
grandpaul said:
You can also wire one or both of the tail light circuits through the light switch, but I don't like to.

Furthermore, you can wire the light switch to the "hot" side of the keyswitch so you can turn on your headlight without the key, but then you've got a possible battery drain if something goes wrong or you forget to turn it off.

Thanks Paul. I'll simply use the diagram and do everything negative ground.

Up here in Canada, the headlight always has to be on. I believe any bike made after 1973 has to be like this.
 
Good posts! My first effort on my 850 wiring wasn't that good. I practiced and learned how to make good terminations, but some of my wires are too long and some are too short. The battery area, where I have my common ground point, is a rat's nest. I'll probably end up ripping it all out and redoing it at some point.

Debby
 
RennieK said:
My 72 harness has 1 or 2 quirks with it like the tributary branching off before passing through the frame grommet instead of behind it like I'd planned. Also there are some tight spots where some of the wires could have been 1/2" longer so they weren't practically trying to pull themselves off their terminals. Although the following may be pretty basic it may help avoid some of these annoyances.

Are you using an old harness as a doner or are you starting with new wire or both? If you use an old harness you can use the coded wires for the same components as in the standard wiring diagram. If you are using a doner harness start by hanging it to the rafters and stripping all the tape off. A razor knife is handy.

Plan where all your components will be mounted. (I concentrated most my electronics at the battery box on my 72)

Plan where your junctions will go. Norton uses the headlight and under the tank as main junction spots so you can disconnect wiring when removing parts for repairs etc.

Bolt all electrical components in position (lights, switches, ignition stuff etc., everything) Tape the barrel (gang) connectors to the frame or where you will be using them. Think of the gang connectors as components like everything else as it's easy to forget them.

With all components fixed in their positions you can start stringing wires. A wiring harness resembles our spinal cord with the bulk of nerves traveling along the backbone. Tributaries branch off and they fork out to the different extremities. Run the long wires first. As you add wires, tape them together with a single wrap of tape when they get close enough to any other wires but leave the ends long. Velcro strips would work better than tape for this when building up the loom as you can more easily open it up and add a wire as you go and you can more easily slide the wires in the loom to remove any slack. As you progress you may find you may want to change how a wire is routed. Main tributaries should follow along frame rails or other components and remain as hidden as possible. By taking the shortest path you may find the wiring itself may hinder the removal of certain parts at a latter date. Before crimping or soldering the ends make sure the run of wire is a little long as you will loose a bit of length when you start taping it all up. You are better to have the wiring a little too long rather than too short where it would pull out from a connection because it barely reaches it. Before soldering or crimping use lots of tape or velcro strips on the harness every 3-4 inches and at branch off points keeping the bundle of wires super tight so the points where tributaries branch off and the wire lengths remain accurately positioned. When it's all tight and in place trim off long ends, crimp/solder and tape it up. It will be easier to remove the harness to tape it up.

I assume you would be using the stock switch clusters on the handle bars. They connect to the main junction block under the tank so you could wire dummy circuits from there to the signals using black wires just taped to the harness and strip them out later.


Great info there so thank you for that.

I'm starting completely from scratch and will not be using my old MKIII harness. It's been spliced and butchered over the years so I want to make a new one as clean and minimal as possible. New wire and conenctions will be used.

I'm using an LED tail light and want to use that as a running light/brake light.

Most of my parts are from CNW so I got a bunch of connectors and bulk wire from them. Ignition will be a Pazon and I'll probably mount the box under the tank somewhere. battery box is off an older bike so I have a bit more room in there to maybe even fit the Pazon brain next to the Sparx rectifier.

So once my harness is laid out, what do you gusy suggest I cover it with? The original seemed to just be wrapped in electrical tape.
 
i use electrical tape, but they sell plastic wrap that you just tape the ends of.
 
RennieK,
Well written and excellent advice.

Doing a harness isn't that tough, but does need a bit of thought before you start.

So once my harness is laid out, what do you gusy suggest I cover it with? The original seemed to just be wrapped in electrical tape.

I like to use loom tape, less messy than electrical tape. A couple wraps with electrical tape or heatshrink at the ends helps to secure it. Some people like the hard plastic split loom cover, but I find it too stiff.
 
Loom or Harness tape is either vinyl or cloth type tape that has either no adhesive or a pressure sensitive adhesive that is used to wrap wiring harnesses. You tightly wrap the bundled wires and weave the end or use heat shrink or electrical tape to keep it from unwinding.
http://www.britishwiring.com/CAT08_09.PDF
 
I'm in the middle of a rewire just now, due to various hints and tips, not to mention encouragement, I received on this forum I have gone for separate fuses and relays. What I did find however, was I learned an awful lot about the wiring and electrical system. For instance the charging circuit can be a small loom on its own! I am putting in a Tri-spark ignition, (I'll worry about the cost later!!!), and I have fitted a Boyer powerbox with warning light. Most of all I was amazed at the amount of wires that I could make redundant. I took advice found elsewhere on the site and all my earths are going to the same point, a bolt through where the old headsteady used to attach, (fitted a Taylor). I put 3 of the 4 relays, the 4th, Ignition, will be fitted at headsteady area, and the powerbox on a board that mounts using the same bolt as the earlier airbox. On the fixing arm I fitted a multi spade connector where all the earths round this area will connect to, the wiring still has to be tidied up a wee bit, see pics. For cable covering I used pvc sleeving and covered it with braided sleeving which , in my opinion, looks better, with the ends closed down with heat shrink.
Good luck with the rewire.... sad I maybe but I'm quite enjoying the challenge!!!!!

http://i411.photobucket.com/albums/pp19 ... yblock.jpg

http://i411.photobucket.com/albums/pp19 ... ckside.jpg
 
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