How to clean / restore wiring harness...

[AAAltered]

Any tips on cleaning this up before I reinstall?  No known issues with it (worked when removed lol) but it's old.  Connectors have grunge on them.  I was thinking a WD40 bath to start.  Then using contact cleaning spray when re-plugging stuff.

[SoCal250]

I have had good success with putting it inside an old pillow case, tying the top closed, then running through the washing machine on gentle cycle with Simple Green.

[m in sc]

wd 40 is what i have used.

[Barrie]

WD40 has the effect of making the insulation go brittle sometimes,
it's initial effect of cleaning up dirty wiring and removing oily residue from connectors give a good initial result,
but long term draw any moisture out of the plastics making them age.

[RattlecanResto]

I throw it in the sonic with diluted simple green

[AAAltered]

Hmmmm I have the three liter sonic.  Maybe I'll try stuffing various endpoints in there one at a time....

I've been running it nonstop for the past few days cleaning other stuff from the disassembly.

[m in sc]

id recommend after cleaning to use some wd to keep any moisture out of the tight spots. that's -actually- what its designed for. 

[Dvsrd]

What about known problem areas in stock RD harnesses?  Like the white 3-wire connector block with AC from the alternator (to rectifier) This is known to overheat, and sometimes melt. If I was to use a stock alternator with a stock harness, I'd definitely try to upgrade that particular area.
Also, if using a higher wattage headlight bulb, like 55/60W H4, heavier gauge wiring, or direct feed via relays is a good idea. And the same goes for the power to the coils.
Whenever posdible, I try to use marine grade, tinned wire for any rewiring. Way better than generic automotive wires.

[m in sc]

youre right, that is a known problem area.
However (and not being argumentative here)...
Here's why: that's caused from a low battery and people using the alternator to charge a weak or failing battery, this overloads the system. the ratings on the leads and connections are well up to task for a healthy bike used with a healthy battery, even with a 55w halogen in the bucket. Many bikes I had seen in the yard that were otherwise stock that had been there for years before the headlights, etc, started going high-draw halogen have had this issue.

to that point, that's USUALLY  what kills a motorcycle charging system in general, IMHO

However, if you're going to upgrade and modify, i def go with weatherpacks or upgraded connectors where i can.

[AAAltered]

Hmmm.  I will be working on the harness today and examine the wiring, especially those noted areas.  I ordered the Economy H4 headlight, that's what I'll be running going forward.

  I am hoping to reuse this harness, the new one for $125 isn't off the table but even with all this bikes been through, none of the issues in the past have come down to the harness/wiring.

[AAAltered]

I have had good success with putting it inside an old pillow case, tying the top closed, then running through the washing machine on gentle cycle with Simple Green.

This sounds great.  Not sure I can do this with the wife around though...

[AAAltered]

I used the sonic cleaner today on the harness.  I did each section for some time, the hot bath allowed me to pull back all the rubber connector covers.  After I did the whole thing I sprayed with WD40.  I also found contact spray in my stash for reassembly.  For now it's hanging in my utility room for a few days to fully dry out...it looks great overall.





Bath got pretty dirty:

[SoCal250]

Nice, it looks good

[pdxjim]

Looks great! 

When reassembling, I always squirt some dielectric grease in the female side of the connector blocks.

Helps to keep the water out and prevent corrosion.  Just a little tho, makes a mess if you put too much.

[2steve]

youre right, that is a known problem area.
However (and not being argumentative here)...
Here's why: that's caused from a low battery and people using the alternator to charge a weak or failing battery, this overloads the system. the ratings on the leads and connections are well up to task for a healthy bike used with a healthy battery, even with a 55w halogen in the bucket. Many bikes I had seen in the yard that were otherwise stock that had been there for years before the headlights, etc, started going high-draw halogen have had this issue.

to that point, that's USUALLY  what kills a motorcycle charging system in general, IMHO

However, if you're going to upgrade and modify, i def go with weatherpacks or upgraded connectors where i can.

REALLY good info there for keeps Mark. I was going to disregard the LED headlight conversion for a while, but now going to move it up to the top.