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Thread: Project Harness Rebuild

  1. #1
    apriliaforum Member
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    Project Harness Rebuild

    Just bought a second hand wiring loom from Ebay and looking to rebuild it.
    I have found I have a small issue with my harness that I worked around to get it going after being off the road for so long.
    Couldn't wait to investigate and properly diagnose so thought it would be good to get hold of an old loom and remake.

    Keeping the original connector housing and replacing all the wiring, sleeving and crimp contacts.
    As my bike is a very early model and problems are only going to get harder to fix with the oxidised wire being hard to work with.

    So will add to this post as the project gets going.

  2. #2
    apriliaforum prov-nov
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    Great project for all of us. Our bikes are getting older year by year and the harness is a weak point. Keep posting any updates and a lot of pictures mate!

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  3. #3
    apriliaforum expert haga lout's Avatar
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    Quote Originally Posted by beasthonda View Post
    Just bought a second hand wiring loom from Ebay and looking to rebuild it.
    I have found I have a small issue with my harness that I worked around to get it going after being off the road for so long.
    Couldn't wait to investigate and properly diagnose so thought it would be good to get hold of an old loom and remake.

    Keeping the original connector housing and replacing all the wiring, sleeving and crimp contacts.
    As my bike is a very early model and problems are only going to get harder to fix with the oxidised wire being hard to work with.

    So will add to this post as the project gets going.
    I’ve a tuono wireing loom if you need any of the connectors Andy you can have it for free if it helps as you’ve helped me in the past

  4. #4
    apriliaforum expert timcrasher's Avatar
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    Good to see you back on the forum. Are you sure you have the skills for such a task
    http://www.youtube.com/user/timcrasher

    http://timcrasher.blogspot.com

    2001 Aprilia Caponord: gone but not forgotten
    2016 Ducati Multistrada DVT ( or should that be PMT ) Flirted with an Italian bella donna but she left me for another lover
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  5. #5
    apriliaforum Member
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    Quote Originally Posted by haga lout View Post
    I’ve a tuono wireing loom if you need any of the connectors Andy you can have it for free if it helps as you’ve helped me in the past
    That's a kind offer and may take you up on that if I get stuck.
    So how it goes when I get the harness set.

  6. #6
    apriliaforum Member
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    I think its a complete harness and not a bad price.
    https://www.ebay.co.uk/itm/APRILIA-C...72.m2749.l2649

  7. #7
    apriliaforum newb
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    I will be keeping an eye on this thread.

    Just bought an eBay harness (US) after reading a few of these threads. Dis-membering it, I find the "pressed-together" junctions, especially the eight-wire blue/red one.

    Tried to flow some solder into it, but the sheer mass of copper overwhelms even my new soldering iron. Think I need a blowtorch to heat up all that copper at once.

    Alternative is to disassemble all the connected wires, and try to solder them one-by-one...multiple problems there.

  8. #8
    apriliaforum Member
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    Had a chance today to give the Ebay harness a clean and to take some photos.
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  9. #9
    apriliaforum expert Nito's Avatar
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    I have some brown connectors if you need them
    2018 Ducati Diavel Diesel "Nel mezzo del cammin de nostra vita"
    2008 Caponord ETV 1000 ABS- "Il Capo"
    2002 Tuono 1000 RSV-R Limited Nr.035- "Hyperthrust Cleared and Counting..."
    1993 Ninja ZXR750R "NinjaR!!"
    1992 Ducati 907IE "Il nostro passato ha un grande futuro"
    1986 Katana GSX750SE "The unbelievable Pop Kat"

  10. #10
    apriliaforum Member
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    Quote Originally Posted by Nito View Post
    I have some brown connectors if you need them
    Thanks Nito that would be great. The brown connector is a little different to the black and green Junior timer connectors.
    So would be a big help

  11. #11
    apriliaforum expert Nito's Avatar
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    Dare I suggest that you might not actually be taking the piss? I’ll have to find and dust them off if you’re being serious. I can’t recall chucking them so they may actually still be in the garage!!

    One thing I noticed on them is the blades are actually quite wide on the brown connectors. I’m using Metripack 630’s on mine.
    2018 Ducati Diavel Diesel "Nel mezzo del cammin de nostra vita"
    2008 Caponord ETV 1000 ABS- "Il Capo"
    2002 Tuono 1000 RSV-R Limited Nr.035- "Hyperthrust Cleared and Counting..."
    1993 Ninja ZXR750R "NinjaR!!"
    1992 Ducati 907IE "Il nostro passato ha un grande futuro"
    1986 Katana GSX750SE "The unbelievable Pop Kat"

  12. #12
    apriliaforum Member
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    Quote Originally Posted by Nito View Post
    Dare I suggest that you might not actually be taking the piss? I’ll have to find and dust them off if you’re being serious. I can’t recall chucking them so they may actually still be in the garage!!

    One thing I noticed on them is the blades are actually quite wide on the brown connectors. I’m using Metripack 630’s on mine.
    You are on about the big brown power connector from the stator? I'm thinking the the brown connector in the photo.
    Thanks but I will give that connector a miss

  13. #13
    apriliaforum expert Nito's Avatar
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    Yes I’m on about the stator/rectifier ones! Didn’t think you’d be wanting them, sorry, didn’t know there were others!!
    2018 Ducati Diavel Diesel "Nel mezzo del cammin de nostra vita"
    2008 Caponord ETV 1000 ABS- "Il Capo"
    2002 Tuono 1000 RSV-R Limited Nr.035- "Hyperthrust Cleared and Counting..."
    1993 Ninja ZXR750R "NinjaR!!"
    1992 Ducati 907IE "Il nostro passato ha un grande futuro"
    1986 Katana GSX750SE "The unbelievable Pop Kat"

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