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The 2-Stroke Garage => Turning Wrenches => Topic started by: bobscyclebarn on August 23, 2019, 06:46:54 PM

Title: rd400 new wire harness
Post by: bobscyclebarn on August 23, 2019, 06:46:54 PM
Hey guys!...I was in the process of repairing a very beat up wire harness, and after 4 hours of soldering broken wires and places someone else had butt spliced, I decided to buy a replace!ent harness.
I am making decent headway, but since Im cleaning up someone else's mess, there are wires that don't have the oe connectors and I am finding the new harness does not have the same color scheme as oe. I do not want to start putting new connectors on until I see if anyone else has further info or diagram for new harness color scheme vs oe.
I have also noticed there was an extra wire grounding the negative to the case, and I am wondering why this was added...there was already a ground coming out from the ignition side of the motor.
This has been a headache project to say the least :wave:
The harness was purchased through economy cycle.

Thanks guys! 
Title: Re: rd400 new wire harness
Post by: Organicjedi on August 23, 2019, 07:21:34 PM
The new economy Cycle harness I used had all the right colors. You're going to have to use the end that connects to the tail light and I think the rear turn signals from the old harness.

The plugs from the stator aren't really secure in the new harness. You'll want to secure those with zip ties.



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Title: Re: rd400 new wire harness
Post by: bobscyclebarn on August 23, 2019, 07:39:01 PM
Thank you...my problem is there have been several people with connectors and crimpers messing with this bike when they aren't qualified to use a hammer.  :taz:
As an electrician, my preference is always solder and heat shrink...butt splices make me cringe, and I spent several hours and used several feet of heat shrink getting rid of them.
Now I'm in the process of making connections behind the headlight and marking each one off of the wire diagram I printed. I'm down to some odd colors that don't match up. I will be at the shop in the morning Workin on it again and can be more specific and take pics.