Hmm, a lot of questions but few answers.
According the the parts manual it looks like the wiring harness should be installed on the right side of the bike, or… not, right side must be wrong. I’m told it right is right, but based on feedback with images I have only got photos from GT380 owners with the wiring harness on the left side of the frame, and it’s the same on my GT750 too. The drawing above must a guidance of how the wiring are connected, not which side it’s fitted.
Based on photos I have got I have some idea about how it should be done. Some advice can also be found on YouTube, but you can’t trust them. Some might be right and some are wrong, and others are horrible wrong.
So, to summarize: I’m not sure, and in some case I don’t have a clue, but I have to start and will use common sense when I have to make decisions. I think a look at mye GT570 will be at a good help. As long as I make it all in compliance with the wiring diagram it should be fine.
Connectors and tools:
I bought a kit from China with a lot of different type of connectors + the crimping tool needed.
In addition I got hold of the upper and lower wiring harness and only need to make some few extra cables to fit into the harness.
The cable from the alternator is already done, please see my previous post. The same for the cable from the ignition electronics (the points )
Next up was the battery cable. That became a bit tricky. Was not able to find the old cable anywhere and how to make a new one. The corresponding connector is made of rubber and how can I make that ? Same procedure as before. I drew the part in Fusion360 and fired up my 3D printer with rubber resin. And here is the result:
I found a picture of the cable on internet and did the measurements on the mating connector from the wiring harness. After printing the part I glued the terminals and added heat shrink to the wires.
The STL file for printing can be downloaded for free:
I inserted the main cable for the upper harness through the lower hole in the headlamp and the upper hole will go to the clocks and and switches on the handlebar. I will use adjustable cable ties for clamping the cable onto the frame so I can easy move and do changes as I continues with the wiring.
That’s enough for today. Will continue another day 🙂