Gamma harness reorganizing, Part 1

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suzsmokeyallan
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Joined: Sat Feb 01, 2014 9:33 am

Gamma harness reorganizing, Part 1

#1 Post by suzsmokeyallan » Sat Mar 25, 2017 9:51 pm

A few photos from when I was doing this work to a harness on one of my Gammas. I wanted to replace the wires that feed power to the ignition coils, one originates from the CDI box and the other from the power valve controller. Mainly the plan for the coil circuit is to use a large gauge wire of a better quality; along with this work I also would get to check through all the wires and replace the spliced tape sections while I had it all open.
I also wanted to move the fuse block to a more convenient place and reduce unwanted wire run, then move the battery wires up to the left side by the indicator relay, add a fuel gauge circuit, a headlamp park bulb circuit, upgrade the high and low beam wires from the switch connector to the bulb socket as those are also under sized, and add a 'pass' circuit to the headlight switch.
Finally I wanted to upgrade the alternator phase wires from the connection to the regulator to a larger 14 gauge size.
I did all the work and left the harness on the bike while all of this was happening, I've done many harness rebuilds and usually I use a template, but for the RG it was just as easy to do the work with it still on the bike due to the way its mounted.
IMG_1648.JPG
IMG_1648.JPG (63.16 KiB) Viewed 1071 times
Fuse block now relocated and minus about five feet of wire.
IMG_1650.JPG
IMG_1650.JPG (77.11 KiB) Viewed 1071 times
New right side ignition coil harness wires and power valve motor connector after retaping. The other sheathing wire is for the low oil level switch in the tank.
IMG_1653.JPG
IMG_1653.JPG (89.43 KiB) Viewed 1071 times
Battery wires in new their new location and the oil tank/battery box. You can also see the new ignition coil wires for the right coil and the fuel sender connection. The harness was routed back under the frame once I had reapplied silver tape to the exposed section thats seen outside the headtube.
The list:
68 Suzuki U70
69 Suzuki T500 MKII
72 Suzuki GT750
74 Suzuki GT750
75 Suzuki GT750
75 Suzuki RE5
76 Suzuki GT750
76 Suzuki TS400
81 Suzuki GSX1100
86 Suzuki RG500 x2
88 Honda CR500
92 Honda CBR900RR
98 Suzuki GSF1200 x3
15 Kawasaki Ninja H2

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