I always fled electrical issues when working on cars, motorcycles - anything. Never really had the time or interest to get into the topic of vehicle electronics. But a few weeks back, the need to upgrade the wiring harness on my beloved thumper started to become very evident: a short to ground from one of the rear light cables, visible copper wires here and there, trouble shooting made difficult from incomprehensive wiring, sticky cables from numerous fixes with electrical tape, parasitic current drain when turned off, excessive voltage drop on startup, etc. There was no turning back, I needed a new harness.
I've stated a number of times how reliability and robustness are the noblest of engineering principles. For the new wiring harness, I would indeed use those as a guiding star. Which means that purchasing a new harness was out of the question. I needed to build one from scratch. And I'm too cheap and too much of a control freak to just leave it to a mechanic. So off I was to autozone and home depot for electrical components.
Reliability and robustness when building a wire harness are achieved following the same three main principles as when building a quality shirt:
With a new wiring harness in place, we could finally get some good miles in this weekend and test out the exhaust system properly. After confirming that the beer can gaskets were working properly, I was ready to wrap the pipes. Doesn't she look pretty?
Not for Pussies!