Mk3 Interstate headlight wiring loom

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Replaced the main wiring loom on my Mk3 last winter, after fitting a 3 phase alternator and Podtronics unit. Unwrapped the new loom, removed all the redundant wires, then re-wrapped. Bike has run for 12 months, no problems.
I now wish to replace the old headlight loom. The original headlight loom has small nylon plugs inside the headlight shell that connects the handle bar switches to the loom. However, the new replacement loom has lots of bullet connectors instead. Just wondering what my options are? Do I find some alternative plugs to replace the bullet connectors or do I just go with the bullet connectors and cut off the handle bar switch plugs and replace with bullets? I've seen some small Molex type plugs that may be suitable.
What do other members use?
Thanks for any advice
 
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325000 thru 327??? are the mostly unknow early wiring. Different WLA (main harness) and 3 extra fuses (headlight harness) complicate wiring exchanges.
Good Luck
 

gtiller

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@Richard Dodds where did you get the replacement headlamp harness?

To my knowledge, both the PVC wrapped Andover one (pictured above) and the cloth wrapped Lucas/Wassell one (WW19133) both have the correct plastic connectors on them for your handlebar switches.

It would be a real shame to cut them off.
 

L.A.B.

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Just wondering what my options are? Do I find some alternative plugs to replace the bullet connectors or do I just go with the bullet connectors and cut off the handle bar switch plugs and replace with bullets?
The 2, 4, 6-pin connectors are available. https://www.tricor-andy.com/product/4-pin-connector/

325000 thru 327??? are the mostly unknow early wiring. Different WLA (main harness) and 3 extra fuses (headlight harness) complicate wiring exchanges.
Good Luck
I believe it's a Canadian 'lights on' model (in NZ) so had the late harness sections although I doubt the switch cluster terminals would have changed between early and late (unless somebody knows otherwise?).
 
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Isn't this the correct harness?

View attachment 17967
Yes, this looks like the correct harness, I can see the nylon handle bar switch plugs. The harness I have is a "British Wiring" one, but it has bullet connectors instead of these plugs. 1975 Mk3 Interstate, Canadian model. After further research, the head light loom I have is made in England, I think that the "British Wiring" ones are made in USA?
 
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@Richard Dodds where did you get the replacement headlamp harness?

To my knowledge, both the PVC wrapped Andover one (pictured above) and the cloth wrapped Lucas/Wassell one (WW19133) both have the correct plastic connectors on them for your handlebar switches.

It would be a real shame to cut them off.
.
Many thanks for your reply. I bought my head light harness here in New Zealand, its made by British wiring and is correct apart from the plugs. It seems to be very well made
 

gtiller

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Interesting - British Wiring was a spin-off from UK company Autosparks - the same people that make the Lucas/Wassell and I believe also the Andover harnesses (the Andover ones are built using better quality components though, compared to the Wassell ones which feel like they are made to the lowest possible price point)
You can also buy them from TMS here in England.

I know British Wiring sold out a few years ago, but I would definitely expect them to still be selling the Autosparks stuff.

Maybe worth dropping British Wiring a mail and asking if they can send you some connectors.
It would be such a shame to chop off the ones on your handlebar switches!
 
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Autosparks do not make a!l the Wassell harnesses, initially they made none and when the faults were found they were used to make replacements. So the only 100% reliable way to make sure it's an Autosparks harness is to go to TMS, not sure about AN either as the example I had needed a new fuse holder after 2 weeks.
 
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Autosparks do not make a!l the Wassell harnesses, initially they made none and when the faults were found they were used to make replacements. So the only 100% reliable way to make sure it's an Autosparks harness is to go to TMS, not sure about AN either as the example I had needed a new fuse holder after 2 weeks.
Many thanks for your reply, can you please tell me whoTMS are?
 

gtiller

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Autosparks do not sell their motorcycle wiring harnesses direct.

In the UK, their preferred reseller is TMS

TMS will also collect all the information needed to make specials too.
 

gtiller

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@kommando that’s interesting about Wassell.

I have tried contacting them a couple of times in the past about the fact the drawings are wrong on a couple of the diagrams they ship in the box with their harnesses.

I was told by them over the phone that the drawings are correct as per Autosparks who make their Commando harnesses and that they wouldn’t be changing them.
 
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When Wassell's first did these green box/bag harnesses it was the first time I had ever heard of a harness not matching the factory wiring diagrams. Wassell's default source is the Far East, I have seen nothing to suggest that Wassel's did not try the Far East first. This resulted in quality issues and they got fingers burnt on certain harness's and only then went to Autospark's to sort it out. Wassell's are their own worst enemy, there are exceptions like the Vape ignitions, but a lot of their stuff is dubious quality and the effort involved in replacing a harness is not worth the potential saving so no Wassell harness will cross this threshold.
 

gtiller

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The two issues I raised with them were based purely on their diagrams - the harnesses themselves were fine.

They were adamant that their diagrams were correct.

0071BFBA-AF08-4DBF-8130-701CCF87762B.png

E9493280-9A2B-4C8B-BF0D-FB5E7579CE1A.png

I totally agree with you that this is an area that you don’t cut corners on!!!
 
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Interesting - British Wiring was a spin-off from UK company Autosparks - the same people that make the Lucas/Wassell and I believe also the Andover harnesses (the Andover ones are built using better quality components though, compared to the Wassell ones which feel like they are made to the lowest possible price point)
You can also buy them from TMS here in England.

I know British Wiring sold out a few years ago, but I would definitely expect them to still be selling the Autosparks stuff.

Maybe worth dropping British Wiring a mail and asking if they can send you some connectors.
It would be such a shame to chop off the ones on your handlebar switches!
Today I emailed TMS, they supply Andover Norton and say they haven't used the original nylon type plugs for years as they caused problems for lots of users.
After 45 years I have had no problems with the original plugs, but have had some problems with bullet connectors
Think I will hunt around for some small marine type connectors and fit them
Thanks for everyones help
 

concours

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Today I emailed TMS, they supply Andover Norton and say they haven't used the original nylon type plugs for years as they caused problems for lots of users.
After 45 years I have had no problems with the original plugs, but have had some problems with bullet connectors
Think I will hunt around for some small marine type connectors and fit them
Thanks for everyones help
 
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Dec 16, 2017
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Replaced the main wiring loom on my Mk3 last winter, after fitting a 3 phase alternator and Podtronics unit. Unwrapped the new loom, removed all the redundant wires, then re-wrapped. Bike has run for 12 months, no problems.
I now wish to replace the old headlight loom. The original headlight loom has small nylon plugs inside the headlight shell that connects the handle bar switches to the loom. However, the new replacement loom has lots of bullet connectors instead. Just wondering what my options are? Do I find some alternative plugs to replace the bullet connectors or do I just go with the bullet connectors and cut off the handle bar switch plugs and replace with bullets? I've seen some small Molex type plugs that may be suitable.
What do other members use?
Thanks for any advice
Have been told by the manufacturer of these looms that they haven't used the nylon /plastic headlight shell plugs for years. They say the small pins were over heating and melted the plug. This is the reason they have gone to bullet terminals
 
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