building a new wiring harness

  • Nessism
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Re: wiring-harness/loom

24 Oct 2025 07:21
#918344
newt14 wrote:
thank you for the input Nessism - 

what ship are you referring to?

Last time I tested them, the RR and stator are functional, although I can test them again.  The harness is very deteriorated.     

I was asking what type of wire is recommended to build the loom with.  I was considering Raychem spec 55.  16 gauge seems the size.  store.emhmotorsports.com/raychem-spec-55-wire-single-core/
The current loom uses multi core - is this single core acceptable for a motorcycle application?  I understand you lose some flexibility.

  

 

 
If the main goal was fixing the charging system, you don't need to rebuild the main vehicle harness for that.  In fact, as mentioned, there is only one wire in the charging system that needs to touch the main loom, the power output wire.  Based on your photo, though, it seems that you made the decision to rebuild the entire harness.  That's the ship that sailed.  
Ed
Carb O-ring Kits : www.kzrider.com/forum/3-carburetor/61807...-o-ring-kits?start=0

www.kzrider.com/forum/faq-wiki/618026-new-owner-things-to-know

1981 KZ750E2
www.kzrider.com/forum/11-projects/604901...z750e-project-thread
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  • H1Vindicator
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Re: building a new wiring harness

25 Oct 2025 08:20 - 25 Oct 2025 08:28
#918364
vintageconnections has wire. made in USA. z1enterprises also has wire. made in china? don't know. could be Taiwan. possibly k&s. if K&L then made in Japan.  cycleterminals has connectors but no wire. afaik. for building a wire harness. if not already owned, be sure to get good tools. worth the cost.
Last edit: 25 Oct 2025 08:28 by H1Vindicator.
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Re: building a new wiring harness

25 Oct 2025 08:24
#918365
newt14 wrote:
79' KZ650 B3

I am looking to build a new wiring harness.  Any recommendations on the type of wire to use?  The most reliable robust option available.

-Rusty
Most reliable and robust?  Get MIL spec wire from Digikey or Mouser.  Teflon coated.  
Ed
Carb O-ring Kits : www.kzrider.com/forum/3-carburetor/61807...-o-ring-kits?start=0

www.kzrider.com/forum/faq-wiki/618026-new-owner-things-to-know

1981 KZ750E2
www.kzrider.com/forum/11-projects/604901...z750e-project-thread
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Re: building a new wiring harness

25 Oct 2025 10:32 - 25 Oct 2025 10:33
#918367
I would go a bit oversize on the wire gauge compared with stock, one gauge up and maybe two gauges up on critical circuits. Use the same wire color coding as the wiring diagram if possible, if not then use colored shrink wrap on the ends (matching the wiring diagram) so you can easily identify circuits. 
1978 KZ650B2 w 1197cc Z1 engine
1977 KZ650B1 w 750cc Spectre engine
1979 KZ650C3 w 831cc Hot Rod engine
1978 KZ650C2 w 762cc DFI project
1977 KZ650C1 stock restoration project
1978 KZ650B2 modified project
1978 KZ650B2 Injected Drag 831cc
1980 Z1 Custom Frame Drag 1327cc
1981 Z50R Honda tow bike
Last edit: 25 Oct 2025 10:33 by Injected. Reason: info
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  • Wookie58
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Re: building a new wiring harness

25 Oct 2025 12:11
#918369
Please try and keep to "one thread per topic" there was already a lot of advice on your other post - I have now merged the two
1982 KZ1000 Ltd
www.kzrider.com/forum/11-projects/617631...-82-begins?start=192
kzrider.com/filebase-alias?view=download...d-fault-diagnosis&ca

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Re: wiring-harness/loom

25 Oct 2025 14:16
#918372
Thank you - very helpful information.  procure multi core wire sized relative to 'current draw' 

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Re: wiring-harness/loom

25 Oct 2025 14:25
#918374
Oh yes, absolutely - I have decided to build from scratch.  Im interested in taking on the project and learning about the different circuits along the way

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