Wireing Harness

[the1pig]

So this winter I am going to rebuild the wire harness due to the fact it has been hacked up one to many times and the connections are brittle.

So the question is should I use the same gauge wire to build the new harness or up grade to a larger gauge wire?

I have received mixed opinions form various people from leave it the same it was built that way for a reason to increase it larger gauge wire better current flow.

Has any one used a larger gauge wire. Also does any one know a good source for weather proof wire connectors. The 82 GS 1100 GK has several 9pin connectors I am hard press to find a local supply of this connector.

Thanks for any info.

Matt

[posplayr]

I think that generally the harnesses are OK, the primary problems is the way the R/R is grounded and connected to the battery.

Both are solved by:

R/R (-) direct to battery (-) and
R/R(-) direct to closest frame ground

U cant do much better than that unless you are doing bare bones harness and minimum use of connectors.

[Nessism]

Hey Matt,

You might want to check out these links... http://www.easternbeaver.com/ http://www.vintageconnections.com/

I'd use the same gauge wire as Suzuki used, you don't want the harness to get too bulky since it needs to snake along the frame and through some openings that are of limited size.

[posplayr]

Hey Matt,

You might want to check out these links... http://www.easternbeaver.com/ http://www.vintageconnections.com/

I'd use the same gauge wire as Suzuki used, you don't want the harness to get too bulky since it needs to snake along the frame and through some openings that are of limited size.

Duh,
Yea improve the connectors will help alot

No double female bullet connectors

[Nessism]

Duh,
Yea improve the connectors will help alot

No double female bullet connectors

I don't think the stock connectors are bad per say, just that after all these years they tend to corrode pretty bad. Worst part about the GS electrical system is the charging system wiring as we all know.

[posplayr]

I don't think the stock connectors are bad per say, just that after all these years they tend to corrode pretty bad. Worst part about the GS electrical system is the charging system wiring as we all know.

The double female bullet connectors are a pathetic excuse for a connector

[doctorgonzo]

I always say this, but when mine burned I got an NOS one for maybe $150 from Bike Bandit. To have all the wire still coded correct to the wiring diagram, and what you'd spend in wire an connectors... I always recommedn seeing if you can fine one.

[doctorgonzo]

Who has shipped and engine?

Ok, I already know, drained, open crated, is the way to go. Any recommendations on the cheapest carrier, or advice? I sold the engine off that RF900 I bought as junk.

[posplayr]

I always say this, but when mine burned I got an NOS one for maybe $150 from Bike Bandit. To have all the wire still coded correct to the wiring diagram, and what you'd spend in wire an connectors... I always recommedn seeing if you can fine one.

+1 me 2 ....

[doctorgonzo]

Ok, I already know, drained, open crated, is the way to go. Any recommendations on the cheapest carrier, or advice? I sold the engine off that RF900 I bought as junk.

Weird... this was supposed to be a new thread...

[Redman]

I dont now that the wire guage of any wire in the harness is undersized. My understanding that wires overheating is due to bad connections from corrossion, heat generated at the connectors.

Have seen references to some supplier of vintage connectors. Dont know what that is myself, perhaps someone else will tell us again.

.

[82gs1100]

I will be going to bigger wires. The stock size works but just enough. you will get more juice to everything if you go up. Go two sizes larger.
Put a relay in for the head light. You can also go to a junk yard and cut off weather pack connectors and solder them in. The stater should not have a plug. run it direct. Also you wont have to worry about burnt wires anymore. Get good automotive wires. Fine strain wire is best. The more flexible the wire the better.

[bonanzadave]

Get good automotive wires. Fine strain wire is best. The more flexible the wire the better.

Better yet get some MIL SPEC wire. M22759/16-(gauge) is an airplane wire with a Tefzel jacket (insulation). Tough stuff.

http://www.aircraftspruce.com/catalog/elpages/unshieldlwire.php

[doctorgonzo]

I dont now that the wire guage of any wire in the harness is undersized. My understanding that wires overheating is due to bad connections from corrossion, heat generated at the connectors.

Have seen references to some supplier of vintage connectors. Dont know what that is myself, perhaps someone else will tell us again.

.

They stock weather shield, bullet connectors, 2 pin, 4 pin, 9 pin etc... connectors, the same styles as on the OEM harness.

[Nessism]

Better yet get some MIL SPEC wire. M22759/16-(gauge) is an airplane wire with a Tefzel jacket (insulation). Tough stuff.

http://www.aircraftspruce.com/catalo...hieldlwire.php

The insulation on MIL spec wire is typically thinner than automotive type wire because it has better insulating properties, and the thinner wire is easier to route on the bike. I agree that it would be a good choice, although an expensive one.