The autumn rain front is active~
It’s suddenly gotten cold, isn’t it? It’s the perfect season for riding bikes.
Harness replacement really does take time~ I’m feeling it deeply…
I used to really hate reusable cable ties.
They’re thick and cumbersome~ that’s what I thought. But wait? They’re actually pretty nice~
• Reusable = if you’re ever stuck somewhere, you can use them again? When you absolutely need to remove them without tools
• The thickness is kindness. Gentle on wire securing with lower contact pressure.
• Perfect for temporary fixing during wire layout.
Reusable cable tie 100mm weather-resistant black 50 pieces RPT-100W50BK
Reusable cable tie 150 black 50 pieces
Reusable cable tie 200 black 50 pieces
I’m using Ohm Electric ones. If you have 100/150/200 mm, I think you can cover most situations.
A subtly effective parts series. The meter gear.
Let’s replace it while we’re at it.
It looks like it’s subtly decreasing… the expected effectiveness might be high.
I put some sponge on it anyway. It does leave marks. This meter might be a slightly risky spot.
The grooves in the meter cover are really well thought out~
They wouldn’t bother doing that nowadays… you can feel the manufacturing enthusiasm.
We’re replacing the right switch for the first time in 200,000 km.
Hmm~ ♪ It fits right on, so I’m happy~ (Most aftermarket switches don’t fit right on…)
From around the 1990s, some main keys have a resistor built in.
If you use an Inazuma 1200 harness with a GSX1100S Katana main switch, the engine won’t start without this resistor, so it’s an important thing to watch out for.
I moved the main ground forward. It’s good to surface the area so the ground drops smoothly.
Sumitomo heat shrink tubing.
It’s good to have various sizes on hand.
I don’t use insulated terminals (male), I handle it with this instead.
There’s no slipping with repeated connections, and the thick wall means no worries.
The solder won’t melt out, so it’s also effective for waterproofing.
I use this when stripping and branching wires too.
【Mysterious Ailment Tall Tale】
A vehicle came in for inspection that had a harness replacement done somewhere else.
On the morning of the inspection
When I backed the bike onto the truck, the engine went “tot-tot-tot-pssst?”
What?? The engine starts but it’s weak… no way~ what could it be???
I’ll skip the long explanation,
but the cause was a single conductor sticking out from the insulation (Sumi tube FZ series) of a wire branched from ON 12V under the seat—unbelievable.
Huh? But the bike was running normally even after the harness replacement… why did this happen at inspection time…?
Apparently it shorted when I started the engine and pressed my hand on the seat.
Modifying wiring = super risky.
The possibility of something going wrong increases ⇒ we want to raise safety, that’s the idea.
Everyone’s troubled starter lead wire.
Most bike models are discontinued… In that case, the GSX-R1100 K-N series is pretty long and works great. 33810-41C00
Keep the side with the clawed angle terminal and cut the other end to adjust the length.
If you crimp and then solder, you’ll increase your peace of mind.
Similarly, if you shrink it with Sumitomo, it’ll look a bit more OEM.
Quimat Soldering Iron Set Precision Digital Temperature Control (90-480°C 1°C increments) LED Display Switch 60W 100V Electronics DIY
I switched from a Hozan station type to this cheap one.
• Light! • Affordable! • Fast heat! • Temperature control!
If you’re like me, turning the power on and off frequently, using it many times, and wanting to use it on thick wires, I think you’ll find it very handy.
* So far, no problems at all. Since I’d be in trouble if it broke, I keep one new one in stock.
Well, we’re doing complicated things for the era.
There wasn’t a super convenient turn signal relay like nowadays…
Lately, it’s amazing that such a small relay can handle hazard functions too.
↑ Don’t accidentally buy one with hazard function~
Total wattage is important.
Still temporarily fixed, but we’re at 95% complete.
【Progress】
9/19
● Harness removal
● Rear turn signal outer covering repair
● Tail light outer covering repair
● Parts procurement
● Meter harness analysis
● Meter harness modification
9/25
● New harness layout
● Meter harness modification (continued)
● Meter wiring assembly and operation check
● Turn signal relay wiring modification
● ETC power acquisition
● Starter lead adaptation modification
● Main key harness modification
● Ground/starter/+lead installation
