Any Interest? - Wire Harness Reproduction

[ps2fixer]

Let me know any suggestions or ideas, I'm all for building adapters to make old harnesses be able to plug into newer parts.

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Color Key:

Green = I can reproduce 100% new parts
Red = I need donor harness to use the plastic shell of connector(s) that I can't source new
Yellow = Requesting photos, if you have the part, please pm or post clear high quality photos

________________________________________________
KAWASAKI
Tecate 1984-1985 - Wire Harness

YAMAHA
YTZ250 (Tri-Z) 1985-1986 - Wire Harness

HONDA

ATC70 All Years - Headlight/Tail Light Wire Kit - Need a set to copy.

ATC90/US90 All Years Wire Harness - Based on my research, all of the 90cc Honda 3 wheelers used the same harness, can anyone validate? Harness does not have the round rubber grommet for the tail light wire.

ATC110 1979-1980 - Wire Harness
ATC110 1981 - Wire Harness - Can't locate quality photos, could someone post/pm me some of the connector ends? I'm 95% sure I can make it based on other years.
ATC110 1982 - Wire Harness - Have not attempted to locate new frame grommets yet
ATC110 1983 - Wire Harness - Have not attempted to locate new frame grommets yet
ATC110 1984 - Wire Harness - Unable to locate new 6 pin round CDI Plugs
ATC110 1985 - Wire Harness - Unable to locate new 6 pin round CDI Plugs

ATC125M 1984 - Wire Harness - Unable to locate new 6 pin round CDI Plugs
ATC125M 1985 - Wire Harness - Unable to locate new 6 pin round CDI Plugs
ATC125M 1986-1987 - Wire Harness - I couldn't see inside the black rubber boot very well, could use photos of that area to validate

ATC185S 1980-1981 + ATC200 1981 - Wire Harness
ATC185S 1982 + ATC200 1982 - Wire Harness
ATC185S 1983 + ATC200 1983 - Wire Harness

ATC200 1981 - Wire Harness - See ATC185S 1980-1981
ATC200 1982 - Wire Harness - See ATC185S 1982
ATC200 1983 - Wire Harness - See ATC185S 1983

ATC200E 1982 - Wire Harness
ATC200E 1983 - Wire Harness

ATC200M 1984 - Wire Harness - Unable to locate new 6 pin round CDI Plugs - There are 3 part numbers for this year, not sure why, one interchanges with 85
ATC200M 1985 - Wire Harness - Unable to locate new 6 pin round CDI Plugs - There are 2 part numbers for this year, one interchanges with 84

ATC200ES 1984 - Wire Harness - Unable to locate new 6 pin round CDI Plugs
ATC200ES 1984 - Keyed Ignition - Ignition switch sourced from china, fairly good quality wires are replaced with GXL wire

ATC200S 1984 - Wire Harness - Unable to locate new 6 pin round CDI Plugs
ATC200S 1985 - Wire Harness - Unable to locate new 6 pin round CDI Plugs - There is 2 part numbers for this year, maybe the 2 plug CDI was introduced this year, if so it should be the same as an 86.
ATC200S 1986 - Wire Harness - Must have 2 plug CDI (4+2)

ATC200X 1983 Wire Harness - Unable to locate new 6 pin round CDI Plugs
ATC200X 1984-1985 Wire Harness - Unable to locate new 6 pin round CDI Plugs
ATC200X 1986 Wire Harness
ATC200X 1987 Wire Harness - Can't locate quality photos, could someone post/pm me some of the connector ends?

ATC250ES 1985 Wire Harness - Unable to locate new pulser connectors and 6 pin round CDI Plugs
ATC250ES 1986 Wire Harness - Unable to locate new pulser connectors
ATC250ES 1987 Wire Harness - Unable to locate new pulser connectors
ATC250ES 1985-1987 + TRX350D 87-89 - Sub Wire Harness for Headlight bulb
ATC250ES 1985-1987 - Headlight Wire Cord - $35 (no gromets, and I'd like to find a thicker tubing to use)

ATC250R 1982 Wire Harness (should fit 81)
ATC250R 1983 Wire Harness
ATC250R 1984 Wire Harness - Unable to locate new 6 pin round CDI Plugs
ATC250R 1985 Wire Harness - Unable to locate new 6 pin round CDI Plugs
ATC250R 1986 Wire Harness - Haven't calculated cost yet (check and make sure you have the 4+2 cdi connectors).

ATC250SX 1985 Wire Harness - Unable to locate new pulser connectors and 6 pin round CDI Plugs
ATC250SX 1986-1987 Wire Harness - Unable to locate new pulser connectors
ATC250SX 1985-1987Sub Wire Harness for Headlight bulb

ATC350X 1985-1986 - Wire Harness
ATC350X 1985-1986 - Headlight Socket Pig Tails (Pair) Sockets are sourced from Honda, so very good quality!

[ebaccm26]

Of course with any service there will be some people interested but I think a lot of people are more likely just to do a quick fix when it comes to wiring harnesses. I do think however that if you reproduced full wiring harnesses that there would be some interest. I know I have had bikes where it would have been a lot easier to just replace the whole harness than to try and repair it and sometimes it can be hard to find one that is in good shape.

[ps2fixer]

I'm thinking the same thing, besides the "quick" fixes being easier and now, shipping to a proper fix, shipping back + the cost of the repair would be about the price of a used harness off ebay.

I was looking at the atc90 harness thinking it would be a great starter project to try, but then I found another member here already makes it. I'll dig around and try to find something different, no reasion to make the same thing someone else makes lol.

http://shop.3wheelerworld.com/index.php?route=product/product&path=304_307_311&product_id=251

I'm looking at possibly an atc70 to start, then maybe move up to a 185s/200s. First thing I'll need is an OEM harness though for measurements and someone to test it on a machine... or maybe I should just go big or go home and do up a 350x harness since I have 2 and my beater needs the stator connecters replaced (came cut off :().

Talking about that, I could refurbish the 350x stators if the actual stator is good and the wires are shot, since the prices are so high on ebay, the repair would be much cheaper!

[RubberSalt]

With the exception of ends, harnesses are to easy to make some quality wire, proper ends and some heat shrink. They have some nifty heat stink ends now. You crimp and heat, creates a water tight seal.

I need to make a tecate harness. I think it consist of a single yellow wire.

I did create 1 for my YT175. Worked out well. With the exception of the wire used for the lighting circuit, Iused trailer wire. Durable multi coated wire. I used a little thicker wire for the lights.

[ps2fixer]

The harnesses I make would be of the same design as OEM, so no heat shrink and such except for the wire loom. This is the type of connectors I use - 3.5mm bullet connectors. The crimper jaws is in the photo as well. I agree that wire harnesses are not really hard to make, just takes time to do it properly. In my case, I would be putting all OEM style connectors on the wire harnesses including the multi-pin connectors, cdi, etc.

[hatc200x1]

I would definitely be very interested if there within the 100-200 dollar range!!! If you decide to do this, you should try and have every Honda 3 wheeler wiring harness available, Or at least the popular ones, 1st gen 200x, liquid cooled 250r, 250es big red, models like that!!!

Go for it man!!!

[ps2fixer]

I would definitely be very interested if there within the 100-200 dollar range!!! If you decide to do this, you should try and have every Honda 3 wheeler wiring harness available, Or at least the popular ones, 1st gen 200x, liquid cooled 250r, 250es big red, models like that!!!

Go for it man!!!

According to the production numbers, the 84 200es is the most popular followed by the 85 250es. Right now I'm trying to source a good supplier for the wire harness wire so I can match the color scheme exactly, since I want this to be a 100% oem replacement harness.

For right now I'm going to target the 85-86 wire harness since it is pretty simple, should be in fairly high demand, and the fact I have two of them to test with, and one of them needs harness work anyway.

Last night I was thinking about this and how to test the harnesses... I came up with the idea of a .... second harness with the opposite ends that goes into a box with lights and buttons to test each pin/wire. Might be a bit of a pain to build, but I would hate to ship something like a harness out with out at least testing it and validating everything has a good connection. This is the main reason I'm sticking with machines I own currently. I have a good share of models, so I'll be busy for a while lol.

Here is the order I'm thinking about building, of course I have to research each harness and make sure I can source all the connector ends.

85-86 350x
84 200es big red
first/second gen 250r (I think they use the same harness? I have an 84 and 82)
first gen 200x
85-87 250es big red (looks like I can build the headlight wire as well since I can get the connector ends, I could even build extension cords for it if someone was interested lol)

If all goes well in sourcing the connectors, I was also looking into building a cdi adapter for the 200es, to adapt from the old cdi box style to the new ones, I read on here that they sourced a good chinese cdi box for cheap, but the connector was the "new style". The kit could come with the cdi box of the known good cdi model.

Oh and yes, I would love to be able to build all models of harnesses, but I'll have to figure out an efficient way to standardize my process so they all turn out the correct lengths and such. As I get them built and stocked, I'll be listing them in the 3ww shop (and ebay at +20% price due to fees) and hopefully the sell fairly well so I can expand to other harnesses.

EDIT:

FINALLY sourced a good quality wire supplier that offers all the color combos I need. Going to order in semi bulk, so I asked for a quote with the colors to make 350x and 82 250r wire harnesses :). I'm going to place an order on the connectors I need now and hopefully in a week or so I can get one done!

[ps2fixer]

It looks like I can make the 85-87 250es and trx350 headlight sub wire harness as well as the 85-87 250sx headlight sub wire harness. Any interest for these?

[Trike_crazy]

Oh and yes, I would love to be able to build all models of harnesses, but I'll have to figure out an efficient way to standardize my process so they all turn out the correct lengths and such. As I get them built and stocked, I'll be listing them in the 3ww shop (and ebay at +20% price due to fees) and hopefully the sell fairly well so I can expand to other harnesses.

199656
You do the harness on a board like this. Just lay out an original harness an trace where all the wires go and terminate. If you have wires that come off the main harness put a nail in the board so you wrap the wire around it so it comes out at the right area on the new harness. You could have a layout of each model and it should be easy to do

[ps2fixer]

That is really crazy, that is exactly what I was planning to do O.o. I guess that is the standard way to build a harness.

Do you know of any quality control methods to validate the harness is 100% correct (pins inserted in the correct locations, no bad crimps, etc)? I know a multimeter would work, but would be time consuming and a good chance of missing the wrong pinout.

[Trike_crazy]

Im not really sure how it could be done easily. I mean if you could make something you could plug the ends of the harness into then have LEDs or something to show continuity then that may work but you would possibly have more time in just making the test equipment. Considering the possible low volume of harness's you would be making it probably wouldn't matter to use a voltmeter. But you never know...

[Dirtcrasher]

You are talking about something that is very labor intensive. Either you enjoy doing it and work for pennies, or pay yourself 25$ an hour.....

[ps2fixer]

You are talking about something that is very labor intensive. Either you enjoy doing it and work for pennies, or pay yourself 25$ an hour.....

It shouldn't be that bad with a good process, how would Honda make these for ~$75 if there wasn't some sort of profit involved. I understand they buy in huge massive quantity so they can get the best prices on the supplies.

Worse case, I'll do this till I break even and just count the time lost as a learning experience and have proper tools for repairing wire harnesses for cars and atvs. I'm not expecting to get rich off this or anything, just to make a little bit of side income.



Im not really sure how it could be done easily. I mean if you could make something you could plug the ends of the harness into then have LEDs or something to show continuity then that may work but you would possibly have more time in just making the test equipment. Considering the possible low volume of harness's you would be making it probably wouldn't matter to use a voltmeter. But you never know...

That is true, I was thinking about a box with leds, but it would take quite a while to build and would cost more than a wire harness to build. I guess the multi meter would be the best option.

[ps2fixer]

Update on this, I looked into the 250sx wire harness, since I just parted one out, and 2 connectors I can't seem to find a source on.

The round 6 pin cdi connector (same as the 1984 200es I think) and the 3 pin connector to the pulser/stator area.

I'm going to update the main post with a list of machines/ possible wire harnesses to reproduce and mark off can/can't as I look into them.

[jeswinehart]

I wanted to post up that I am thoroughly impressed with the 350X headlight bulb/socket/wiring harness set up I got from you last year.
Top notch work !

john

[ps2fixer]

I wanted to post up that I am thoroughly impressed with the 350X headlight bulb/socket/wiring harness set up I got from you last year.
Top notch work !

john


Thanks for the feed back John, I can't believe it has already been a year O.o.

[ps2fixer]

Got a couple of packages today! Wire and a bunch of connectors. Built a wire harness board (helps a ton!) and stripped down my beater 350x wire harness down to the wires, and found a couple of bad spots where it was being pinched by the air box >,<.... it needed a harness more than I thought. Harness isn't done, but ~95% done, waiting on a special tool for the coil connecters, and I bought the wrong sized ring terminal for the frame ground. Here are some photos, 3 of the harness on the peg board, and the nearly complete harness.

I did the math... and I can sell the 350x wire harness for $65 + shipping. I have supplies for 1 more, first one is going on my machine :). I won't be able to ship one out for around a week as my service manual didn't match the color scheme, so I had to use a wrong color wire to make my current harness.

[The Goat]

I would be more interested if you allowed certain mods to be requested.

IE... a battery input for a 350x, or a functional tail light, or dash lighting, the addition of a keyed switch, and so on.

These things help.

[ps2fixer]

I have no problem with custom requests, the only real problem is placing the connections correctly on the harness, and I would probably have to have photos of the connections so I can color match and match the connection types.

By functional tail light, you are talking about one hooked up to a brake switch that makes it get brighter when you hit the brakes?

[Dirtcrasher]

So do you sell an 86 350X harness?? Or are you still looking for interest/buyers for it??

[ps2fixer]

I have supplies to make about 3 more, I haven't made time to finish the first one I was working on, the tool I got for crimping the "flag" connector for the coil isn't as good as I hoped for. I might have to buy a 60-70w soldering iron and fold the tabs over and solder it since I can't get a good crimp.

To answer your question, if someone is interested in buying one, I can make it, but I don't have any pre made for shipping so there will be a small waiting time.

I just got home from my parents house where my nice 350x is and I noticed it's wire harness isn't as nice as the rest of the machine :(, going to have to make one for that too I think lol.

[250rRoostmaster]

I would be more interested if you allowed certain mods to be requested.

IE... a battery input for a 350x, or a functional tail light, or dash lighting, the addition of a keyed switch, and so on.

These things help.

Brakes lights are easy. Just get a banjo bolt switch and wire it up (pressure activated switch). I put one on my R and it works great.

[Dirtweed]

I'd be up for a '82 250R harness. Since I am doing the restore that would be perfect. I'm an idiot when it comes to making
something like this.....and most things.

[250rRoostmaster]

Where are you buying OEM style connectors if you don't mind me asking?

[ps2fixer]

I buy most of the connections from http://www.cycleterminal.com. Joe is a great guy to work with, and very prompt on responding/shipping. Prices are probably a little higher than other places, but all of the connectors I have bought from him so far have been really nice quality.

Just in case anyone is interested, I use GXL automotive grade wire. This wire is certified up to 125C and resists weather, oil, and grease, typically is used in the engine bay of a car.

FYI, the OEM style terminals and connectors require special tools to crimp. I haven't found an inexpensive "flag" terminal crimper yet, cheapest being like $100. I have a tool that does ok for the current time.

[Dirtcrasher]

Sounds good buddy, I may buy your first set if it looks great and functions perfect.....

[ps2fixer]

Sounds good buddy, I may buy your first set if it looks great and functions perfect.....

I'll put you next in line :). Dirtweed is having me make a 250r harness. The harness I already made I need for my 350x, since I sacrificed it to rebuild them the exact layout that Honda built them.

[250rRoostmaster]

I would probably be interested in an 85 250r harness. I don't know if i'll ever have time to make one. Though it does looks kinda fun.

[ps2fixer]

I would probably be interested in an 85 250r harness. I don't know if i'll ever have time to make one. Though it does looks kinda fun.

I took a quick peek on ebay, and it looks like there is two styles used for the CDI plugs, the single plug 6 pin connector that I can't find a source on, and the 2 plug 4+2 style connector that is common through present. If yours is the single 6 pin connector, I'll need at least the connector sent to me to reuse the outer shell/holder of the pins as long as it is in good shape. I can get the rest of the connectors new.

[ps2fixer]

I'd be up for a '82 250R harness. Since I am doing the restore that would be perfect. I'm an idiot when it comes to making
something like this.....and most things.

Here is the 1982 250R harness I made today, photos didn't turn out the best, for some reason the flash didn't go off. The taillight wire is about 8 inches longer than stock as requested. I jumped the gun a bit early and started putting connectors on it, so I couldn't put the tubing on it. It is electrical tape warped instead, and this isn't the cheap electrical tape found in most stores, this stuff is $6.50 a roll and safe up to 105C. If you prefer the tubing, I can make another one and offer this one up for sale.

Total will be $75 including shipping. I'll pm you payment details.

[250rRoostmaster]

I took a quick peek on ebay, and it looks like there is two styles used for the CDI plugs, the single plug 6 pin connector that I can't find a source on, and the 2 plug 4+2 style connector that is common through present. If yours is the single 6 pin connector, I'll need at least the connector sent to me to reuse the outer shell/holder of the pins as long as it is in good shape. I can get the rest of the connectors new.

I could do that. I have a extra old harness that I could use the connector from.

[ps2fixer]

I could do that. I have a extra old harness that I could use the connector from.

Since you have a spare harness, could you send it to me so I can copy it the same way Honda built it? The other option is to measure each section of the wire, but it won't be quite as accurate.



Back to the 82 harness, Dirtweed desided to go with the tubing, so the vinyl wrapped harness is for sale here:
http://www.3wheelerworld.com/showthread.php/169799-New-%28reproduced%29-1981-1982-ATC250r-Wire-Harness

[250rRoostmaster]

[QUOTE=ps2fixer;1330467]Since you have a spare harness, could you send it to me so I can copy it the same way Honda built it? The other option is to measure each section of the wire, but it won't be quite as accurate.



Sure can, i have no use for it at the moment!!

[ps2fixer]

Does anyone know the difference between the 81 and 82 250r wire harness? They are different part numbers, but use the same part diagram.

I'm going to be ordering some new harness tubing in high gloss as another option mainly for looks.

[ps2fixer]

Sorry for the lack of updates. I did some clearing out in my work area to get a better setup for making the harnesses. I also have an idea on a better "peg board" setup instead of just using nails. I'll post some pics if it works out well.

Finally, I have been searching for some companies that specialize in making harnesses in low quantity bulk to get an idea if that route would be better than doing everything 100% myself. I'll have to make up a CAD drawing of the harness design to be able to get an accurate quote, so that might take a bit as I'm pretty new with CAD.

I didn't get a chance to research the 81 vs 82 250r harness yet, I would like to say they interchange, but maybe a wire section is shorter on one or something like that.

[manbearpig]

the 81 had the kill switch on the throttle housing and the headlight switch on the left side of the bars. 82 had kill/light switch combo (like 185S) on left side of the bars. thats the only difference between the two harnesses

[ps2fixer]

the 81 had the kill switch on the throttle housing and the headlight switch on the left side of the bars. 82 had kill/light switch combo (like 185S) on left side of the bars. thats the only difference between the two harnesses

Great info. By chance do you know if any of the connections changed? I looked at some photos again and I can see the headlight wire comes out of the harness a bit different, but the cluster of connections I can't find any good photos on.

[ps2fixer]

Update for today, I figured out a different process, and so far it seems much faster to get the correct lengths of wire cut and held in place. Before I was fighting the other wires to measure new ones and comparing colors with the oem harness in the mix. You can see my super great art too!

Sorry the photos are not the greatest, using a cellphone instead of a real camera.

[manbearpig]

Great info. By chance do you know if any of the connections changed? I looked at some photos again and I can see the headlight wire comes out of the harness a bit different, but the cluster of connections I can't find any good photos on.

cant remember off the top of my head. i tucked away a couple 81 throttles, headlight switches, and i think a wiring harness. i'll dig em out tomorrow and will snap some shots and send them over

[ps2fixer]

cant remember off the top of my head. i tucked away a couple 81 throttles, headlight switches, and i think a wiring harness. i'll dig em out tomorrow and will snap some shots and send them over

Wonderful, I can compare them with my 82 harness since I haven't installed it back in my machine yet.

[slashfan7964]

I fully support this and I'll be promoting this to a front page article tomorrow in hopes it gets you more business. Thank you for your time and effort in reproducing such a major component.

[ps2fixer]

I fully support this and I'll be promoting this to a front page article tomorrow in hopes it gets you more business. Thank you for your time and effort in reproducing such a major component.


Thank you for the acknowledgement and the efforts to get me more business! Do you need a quality photo for the article?

I have been talking to my dad about getting him trained and have him help me make the harnesses if I somehow get swamped.

[slashfan7964]

Thank you for the acknowledgement and the efforts to get me more business! Do you need a quality photo for the article?

I have been talking to my dad about getting him trained and have him help me make the harnesses if I somehow get swamped.

It would be best, as all I am going on right now is one of the photos you provided on page 2, but it is not necessary. If need be I'll wait and put it up sometime Sunday if you want to provide a better photo as I'm not sure when I'll be able to get online and swap them over before it goes live; and I would want to get it up before tomorrow. At the moment I have it scheduled for Sunday afternoon, so if you can get it to me before hand that would be great.

[ps2fixer]

I'll get my real camera out and take some real photos. I'll post them up here so others can see everything much better. I have a 350x harness I just about have done (wired up on the board) so I'll target finishing it up today when I get home from work and take photos along the process.

[slashfan7964]

I'll get my real camera out and take some real photos. I'll post them up here so others can see everything much better. I have a 350x harness I just about have done (wired up on the board) so I'll target finishing it up today when I get home from work and take photos along the process.

Sounds good, thanks.

[slashfan7964]

Sorry for the double post, what's the deal with 200X's? I noticed you don't have them listed but most everything else, and X's are arguably one of the most common machines. Any chance?

[ps2fixer]

Sorry for the double post, what's the deal with 200X's? I noticed you don't have them listed but most everything else, and X's are arguably one of the most common machines. Any chance?

It is one of the machines I missed, There is also 200m and such, so I added the x to the list to research :).

Here are the higher quality photos from an actual camera.

[slashfan7964]

Thank man. I'll use those for sure.

[jakep53]

this is a great thing you're doing!!
in the future I would be interested in 1st gen 200x, 2nd gen 200x, 200es 82 r, and maybe some other but in a few months i would be up for a couple at least the 1st gen x wiring harness but I just can't afford it yet lol

[ps2fixer]

Updated first post with a much easier to read list of the harnesses and researched a ton of models/years. The year ranges are based on part number, so some years might overlap due to small changes that don't effect interchangeability.


Anyone have a ATC70 light kit? Of what I can see, I can reproduce the harness no problem, but the problem is getting one to copy. I can copy the harness with out damage to the original.



this is a great thing you're doing!!
in the future I would be interested in 1st gen 200x, 2nd gen 200x, 200es 82 r, and maybe some other but in a few months i would be up for a couple at least the 1st gen x wiring harness but I just can't afford it yet lol

I'll need exact years as the harnesses change quite often. Thanks for the positive reinforcement, been a lot of work, but things should smooth out once I'm done researching and get most templates made :).

[rdonald1979]

This just goes to show how much passion there is for these "Banned Machines". Keep up the good fight!

[ps2fixer]

This just goes to show how much passion there is for these "Banned Machines". Keep up the good fight!

I'm fighting! lol


I think I have all of the Honda ATC models listed now. Looks like there are two evil connectors that hold me up from making the first page all green.... the 6 pin round cdi plug, which I'm pretty sure can be adapted to the 2 plug 2+4 cdi plug, but a suitable cdi has to be found per machine, and the 250es/sx's pulser connector.

According to this post, the 85 250es can be adapted to the 2 plug cdi and use a new cdi from an 86-87 big red.
http://www.3wheelerworld.com/showthread.php/160642-Needing-a-CDI-box-for-atc-Honda-250es?p=1248363#post1248363

I'll work on getting Yamaha and the other 3 wheeler brands listed up that were mass produced as I get time. The more rare models I'll place in the custom harnesses since there probably isn't enough people needing them to justify the effort until someone wants one. Also to be clear, I can do quad harnesses as well, but right now my main focus is 3 wheelers.

[ps2fixer]

Made a couple more templates today. 1985 ATC250R and ATC90 (based on my 1978 harness). The ATC90 ones will be pretty cheap priced since they are quick to build, the template only took me around 30 mins to setup! I had to get the multi meter out though as the green/black wires are not all the same connection. Kind of a strange setup, but I'm sure Honda has their reasons.

I'm waiting for an order of larger sized heat shrink to come in before I get some harnesses finished. Have 2x 350x prepped, the 85 atc250r for 250rRoostmaster, and one atc90 harness.

[ps2fixer]

Sorry for no updates in a while, work has been pretty killer this week so far. Tomorrow I'm going on a work related trip (last minute like normal).

Anyway for updates the following items showed up high gloss pvc harness tubing, large order of vinyl tape (20 rolls), large sized heat shrink (might be slightly too big for some spots on the harnesses). I'll be assembling harnesses as I can make time.

Thanks for everyone's interest so far, and hopefully before long I can get some solid feedback about them :).

[The_Steve_Man]

If I have the CDI plugs for the 85 and 86 250r you can make the harness? I have 2 hacked up 86 harnesses and an 85 harness.

[ps2fixer]

If I have the CDI plugs for the 85 and 86 250r you can make the harness? I have 2 hacked up 86 harnesses and an 85 harness.

Yes, for me to make the 1985 atc250r harness I will need your old one with a good cdi plug (just the plastic part of it). As for the 86, I can get all the components new. From the limited research I have done, quite a few machines with the round cdi plug (85 r in your case) can be upgraded to the new style cdi plug if you replace the cdi as well. Most likely the 86 cdi box would work on an 85, but I have not researched it. The plug can be changed at a later date as well, I was planning to make a write up about the "correct" way to upgrade the harnesses with a few low cost parts/tools.

[OKSTATE#1]

Just saw all this. Helluva deal! Dang...if I still had my 86 250ES all in pieces I would have gone this route fo sho. I had to do some repairs, but I wished I would have just changed out the whole damn show.

[oile]

hey can you do the headlight pig tail for the 84/85 tecate

[ps2fixer]

hey can you do the headlight pig tail for the 84/85 tecate

Could you post/pm me some photos of the highlight lead wire harness? It looks like it uses the standard H4 highlight plug, if so I can remake them for around $20.

According to this page, it looks like Kawasaki still makes this part -> http://www.partzilla.com/parts/detail/kawasaki/KP-26011-4011.html

[ps2fixer]

Here are photos for Dirk D.



Update for this thread, I'm on vacation now (from work), and plan to really get some stuff done. I also placed an order for a new crimper tool to make battery cables from small to very large (like EV battery bank sized) lugs. I'll have to play around with it some, but my toyota pickup could use a new battery cable lug crimped on it, so I can put the two wires together, instead of having it semi-rigged with 2 cables. This would be mainly targeting the 250es/250sx battery cables, but I know other models use batteries as well.

Also got another shipment of wire in, I ran out of brown, that won't happen for a while now since I bought 100ft instead of 25ft.

[Dirtweed]

I received my wiring harness the other day for my KLT160 and it looks great.

203809 203810 203811 203812

[ps2fixer]

Updated first post to reflect order changes.

My day job has been pretty crazy lately, and I'll be traveling for work at the end of the month into December. Hopefully between now and then I'll get most of the harnesses on order finished.


@Dirtweed

Thanks for the photos, it is funny how they come out so much better than my camera :D.

[ama009]

I need one for my 85 tri-z!

[ps2fixer]

Just to verify, does this look like your harness?

http://www.ebay.com/itm/1985-Yamaha-Tri-Z-250-TriZ-250-Tri-Z-Main-Wire-Harness-For-Parts-Or-Repair-Only-/121481847500?pt=Motors_ATV_Parts_Accessories&hash=item1c48e1e2cc&vxp=mtr

The only thing I'm not sure on is the box with the black/brown wires. Everything else looks to be the standard connectors I have on hand. If the black box unplugs from the main harness, I probably can assemble the whole harness new, if not I'd probably have to have an old harness to add inline connections for it and use a short section of the old wire to match the new to the old.

Just for a general idea on the price, I don't think it would be any more than $65, my guess would be closer to $50, but I'd have to get one in my hands to calculate the cost/price.

[ama009]

I can send u mine so u can replicate. The one u posted looks great! Price sounds good to me! Pm me address and paypal.

[big specht]

Did you every have any luck finding all the connectors for a 86 big red harness? I have one that has broken wires around steering head area

[ps2fixer]

Did you every have any luck finding all the connectors for a 86 big red harness? I have one that has broken wires around steering head area

There is a couple of the connectors I can't get, but I can rebuild a harness with the plastic shell of your old harness if the connectors are good and put new pins in them. The big reds and the 250sx are a bit more expensive since they have a lot more going on in the harness compared to the sports models.


Also as an update for this thread, I'm planning to make a web interface to make it easier to order/request harnesses to be made, and to help me keep track of everything better. The page probably won't be finished by this year end, but I'm hoping for first qt of 2015 :).

[Dave Little]

There is a couple of the connectors I can't get

Hey, good work you are doing- I was rummaging through my collection of SX harnesses and I've got a 6 pin CDI connector if you want it. both my machines and the basketcase I've got use the 4+2 and I've got two spare harnesses that are also 4+2 so 6 pin is useless to me but someone may need it. If you want it, it's yours. Also sure I have pulser connectors but not sure what that is- I'll have a look at the manual later today.

[ps2fixer]

Sounds great. The pulser connector is a round housing and inside is a squared off c shape in the center. I think it was 3 wires but im not 100% sure.

Thanks!

[ps2fixer]

Update for the thread, 1985-1986 Tri-Z harnesses I can get all the connectors for! I updated the first post to reflect this.

[Dave Little]

Sounds great. The pulser connector is a round housing and inside is a squared off c shape in the center. I think it was 3 wires but im not 100% sure.

Thanks!

Oh, The Paul Sr. connector- got three of them you can have:
http://i719.photobucket.com/albums/ww200/QuantumDave/Rides/IMG_2305.jpg (http://s719.photobucket.com/user/QuantumDave/media/Rides/IMG_2305.jpg.html)

[Dave Little]

These will be wheels up by the 'morrow
http://i719.photobucket.com/albums/ww200/QuantumDave/Rides/IMG_2316.jpg (http://s719.photobucket.com/user/QuantumDave/media/Rides/IMG_2316.jpg.html)

[Xowner]

Wiring harnesses still being made? I need an 85 R harness and a 86 R harness i know you need my connector off the 85. How much are these ?

[hogmuffin]

I think this is a great idea. My 85sx harness is shot. It would be awesome if I could replace it with an all new one.

[manbearpig]

PS2FIXER,


Please respond to my emails and send my parts back.


thank you

[thcowboy]

Yeah i thats a great idea if i ever need a harness ill get one from you :)

[ps2fixer]

Wiring harnesses still being made? I need an 85 R harness and a 86 R harness i know you need my connector off the 85. How much are these ?

I don't have the costs etc setup in my excel sheet, but going off the 81-82 harness it should be $75 each give or take $5. I'm pretty back logged on orders right now so it will be at least a month, or even months before I'll be able to get to yours.



PS2FIXER,


Please respond to my emails and send my parts back.


thank you

I wasn't keeping the best eye on the thread, we are chatting via email :).

[oscarmayer]

seen some of his work. amazing quality and craftsmanship!

[roadmaster]

I am interested in a 1979 atc 110 wiring harness. Do you have everything to build one and what is the price?

[BarnBoy]

If you find a source for the round 6 pin cdi plug id buy a 200M harness off ya.

[ps2fixer]

I am interested in a 1979 atc 110 wiring harness. Do you have everything to build one and what is the price?

Sorry about the delay. I don't have the 79 atc110 harness made and my source harness isn't in very good shape so there's a couple things about it I'm not 100% sure on for layout and such. For the time being, it's probably best to watch ebay for a good used harness.





If you find a source for the round 6 pin cdi plug id buy a 200M harness off ya.

I've been watching for that connector for years now, still no luck. I do have access to make adapters though to go from the round 6 pin to the modern 4+2 style connector. That would open up aftermarket CDI's, same ones that work on the 200e/es should work on the 200m. For an OEM option, I'm pretty sure the 86 atc200s CDI would work but they aren't exactly super common place.

[badasskfx]

I would like to get a harness for 1986 350x let me know when it’s ready and where to send payment.
Thanks

[MrConcdid]

I would like a harness for a 1985 350x.
Please pm for paypal
MrC.

[badasskfx]

https://www.ebay.com/itm/1985-1986-85-86-Honda-ATC-350X-wiring-harness-OEM-replica-reproduction/174291575280?hash=item28949661f0:g:NhAAAOSw~vxeyCG A
I bought this one it looks good haven’t installed it yet.
Ps fixer said he was to busy a while back. Send him a pm for better response.

[MrConcdid]

I did send him one a few days ago, He hasn't responded, that why I dug up this old thread. Does anyone have a phone number for him?
Id rather give him the business if I can.

Does the one you link to have the headlight pigtails?
thanks
MrC.

[badasskfx]

No I does not have the headlight pig tails.

[ps2fixer]

Sorry about the delay, I always get too many projects going on. I replied to the pm.

I've ordered more source parts for the 350x headlight sockets a day or two ago, the prices all jumped up on me though so probably a limited number left for Honda sourced sockets before I have to switch to aftermarket.

I've seen those harnesses made that was linked above, it appears like they used heat shrink to "tube" the harness wires. Not sure how great that will last long term or how well it holds up against heat, uv, etc. Besides that the quality of what I can see in the pics don't look bad, atleast better than Chinese knock offs I've seen over the years. I do see the ground ring terminal crimp isn't super great, the wire doesn't extend past the crimp area at all, but it's really hard to judge things based on just a hand full of photos, most which don't show the crimp side of the terminals.



I also recently found out the ignition switch I buy from Honda to mod for the ATC250SX has just been discontinued. The price jumped up about 20% and I bought a bunch off a dealer that has them in stock. He said the ATC250ES ones are still in production. I suspect those will be next though. I bought an aftermarket switch body to test too for a cheaper alternative since the Honda source parts are getting quite expensive now.