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Katana 550 Rewire

  • Thread starter Thread starter barrykatona
  • Start date Start date
B

barrykatona

Guest
Hi guys,

Whilst i am looking for my replacement engine i have been having a look at the electrics.And they look about as good as the engine:cry:

Was wondering if anyone had info on rewiring the bike (hopefully with less bulky harness) and perhaps with better alternative parts (Honda R/R i hear people talking about)

As it is a complete rebuild i would feel better with a modified rewire with less wires and more modern parts.

Ideas and opinions please.



THIS KAT WILL WAIL AGAIN (just not sure when)\\:D/
 
Several rough guides have been posted. One suggested supplier was

www.midwestactioncycle.com.

I'm pretty sure that NAPA can get almost everything.

Other advice I've read (little experience myself)

>Use genuine Moles connectors and crimping tools
>Don't use cheap crimping tools - their connections suck.
>Use dielectric grease/compound to keep air and moisture out of connections. It shoud make corrosion take a lot longer.
>Use the same gauge of wire as stock. Larger gauges are harder to route and less flexible. If heavier wire is used, make pieces a bit longer to compensate for larger radius turns.
>Remove all tape around the harness to expose all connections.
>Replace one wire at a time.
>Use different colors, stock if possible. Trying to figure out which wire is which without color codes can make repair and troubleshooting take forever.
>Work slowly and patiently.
 
GS550Wiring003.jpg
I just started rewiring my 85 GS550, took all the tape off, greased all the connections and replaced corroded ones. I checked the continuity of every connection, time consuming but worth it.
 
Thanks for that guys and thanks for the great picture. Looks like i have a task to occupy those long cold winter nights.:-D
 
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