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alexandervf

The Rebirth Of An Rvf400 Wire Harness....

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Hi to everyone once more.........

As the title states,

i decided about a year ago, after facing a few (Critical) electrical problems to build ,reconstruct,revive ... you choose the word that suits best, the whole wiring harness.

The wire used for the job was a high grade teflon coated wire with silver plated strands bought from the US. The connectors are new type, splash proof, sumitomo's and furukawa's from Japan.

I have also rewound my stator, made new spark plug wires installed the (rare to us here) ER9EH IX spark plugs and replaced almost every incandescent bulb with leds. A volt meter has been installed as well.

There were a few more jobs done as well which i will show you ..... So....

These are spools that were used (there are more, they were on pending orders)....

AXL_4661_zps6a6b3057.jpg

Here you can see the spark plug wires.....

AXL_4663_zps4d0a8ed4.jpg

I had to... lets say... "modify" some older spark plug wires in order to "extract" the part that i needed...

AXL_4662_zps538d5fb9.jpg

In the following photos, you will see the connectors used for the harness....

AXL_4635_zps6370e203.jpg

AXL_4634_zpsfed40a20.jpg

AXL_4633_zps83a7e372.jpg

AXL_4632_zpscb0d96e8.jpg

AXL_4631_zpse416ce98.jpg

AXL_4630_zpsa2f68604.jpg

AXL_4629_zps3c9dfe00.jpg

AXL_4628_zps90e4372e.jpg

The following photos show the beginning of the harness build....

AXL_4682_zps135f162c.jpg

AXL_4687_zps180aabf0.jpg

AXL_4685_zpsbc6c1e9f.jpg

AXL_4683_zps8d4d6d7d.jpg

AXL_4684_zpseb35dc40.jpg

Smaller clocks loom...(did not mess with the T10 rubber bases, could not find them anywhere on the internet as a oem part)....

AXL_4660_zps1b11833d.jpg

Side stand switch.....

AXL_4659_zpse79e8dfb.jpg

Main keyswitch / ignition....

AXL_4658_zps9368fbd9.jpg

Tail light loom....

AXL_4657_zps598a91ce.jpg

Left hand side switchgear......

AXL_4678_zps4752352c.jpg

AXL_4675_zpse3d0d484.jpg

The Left hand side switchgear was later replaced by a cbr900 left hand side switchgear such as this one.....

L-Hswitchgearcbr900.jpg

The right hand switchgear.....

AXL_4656_zps96a42b29.jpg

....Which was later replaced by a CBR600 right hand switchgear such as this one.....

Killswitch2cbr60007.jpg

As i said above.....leds almost everywhere....

The clocks....

AXL_4701_zps326bc551.jpg

AXL_4702_zps5f58ecf5.jpg

AXL_4704_zps68cee4e5.jpg

AXL_4700_zps5a7fd6fd.jpg

AXL_4698_zps25f533d3.jpg

AXL_4696_zps03224d90.jpg

.....And the tail light unit....

0042_resize.jpg

0041_resize.jpg

0045_resize.jpg

0043_resize.jpg

AXL_4014_resize.jpg

AXL_4013_resize.jpg

.....Testing of the tail light...

AXL_4005_resize.jpg

AXL_4004_resize.jpg

The stator.....a painful job...but very rewarding if done right.

Here is what it looked like before i messed with it......

AXL_4727_zps472f1bb2.jpg

AXL_4725_zps26390b97.jpg

The core...cleaned...

AXL_4736_zps6c02c9c3.jpg

AXL_4738_zps89106147.jpg

Preparations for the rewiring of the core....

AXL_4772_zps4cf95f67.jpg

The stator....FINALY....ready to be submerged in the special resin...

AXL_4774_zps5cff1902.jpg

AXL_4775_zpsfbc5a1b1.jpg

Submerging the stator in the resin...

AXL_4781_zps1439cce0.jpg

AXL_4780_zpsba3eb7f7.jpg

The stator...ready for installation...

AXL_4794_zpsa9012765.jpg

AXL_4793_zpse331aefe.jpg

The volt meter .......

Voltmeter1_zps385033c1.jpg

AXL_4846_resize.jpg

AXL_4845_resize.jpg

AXL_4844_zps6f0c375a.jpg

Thermo-switch / sensor, so that it triggers the cooling fan when the R/R reaches 46 degrees Celsius .....

AXL_4720_zps10003e22.jpg

AXL_4718_zps1db93009.jpg

AXL_4714_zpsf9abe488.jpg

Other mods....

Hand made R/R stainless steel base...

AXL_3964_resize.jpg

AXL_3965_resize.jpg

AXL_3966_resize.jpg

AXL_3963_resize.jpg

Relocating the R/R under the pillion seat ....

AXL_3971_resize.jpg

AXL_3970_resize.jpg

Hand made stainless steel V-piece mesh....

AXL_3598_resize.jpg

Top radiator hand made stainless steel mesh (front and rear of the rad).....

AXL_3882_resize.jpg

AXL_3881_resize.jpg

AXL_3878_resize.jpg

AXL_3877_resize.jpg

TIP: Some of you may already know it , some of you may not. If you are about to mess with teflon coated wires they do not strip the usual way.....You will need a special tool for striping teflon wire insulation.

If you do not have the money for such a tool (I did not) you can make it like i did....you will have to brake down one of these....

AXL_4771_zps2c0d43b8.jpg

and make something like this....

AXL_4766_zpsef4aeef2.jpg

This was a job that took almost a year to complete. It was a painful job (especially the stator) but i very much enjoyed it because i LEARNED A LOT.

Thanks for reading.

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Wow, fantastic! That's some impressive work. :fing02:

:cool:

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Wow! Persistence, ingenuity, and beautiful work. Thanks for sharing!

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WOW! Just... WOW!!!

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You sir, are the most patient man in the universe.

How about a few beauty shots of your 400 from afar?



Oh, and I have always hated how Honda uses real thin wire gauge for their harnesses, and hides crimped splices in the middle of the harness instead of using one whole piece of wire.

I would LOVE to rewire my bike, and use quality heavy gauge wire, but it would be 10 times the work of your carbed 400, due to the Fi and electronics.

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Outstanding. Nicely done! :fing02: If the rest of the bike is anything as nice as the wiring, it's beautiful. Thanks for all the pics - we'd love to see more!

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Here are a few shots of how my bike looks today.....

AXL_4883_resize_zpsaf8e0509.jpg

AXL_4881_resize_zps7209a09e.jpg

AXL_4879_resize_zpsc06adb85.jpg

I have also done the carbs.... pics will follow....soon....

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It looks.........like a 2013 RVF400!!!!!!!!!!!!!!!!!!!!!!!

I think I know just where to put this.........

AXL 4881 resize zps7209a09e

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Due to the fact that i had plenty of time waiting for the spools to arrive, i said, why don't i give a good clean treatment to my carbs....what do i have to lose???

Yes right.....Take a look what i found .....The "No brain left" "Neanderthal" mechanic that i trusted him with my bike had a "faster" way in his mind of removing the carbs from the bike, obviously, he hit them from underneath.....The result a good size crack....

AXL_3577a_zps2f999c3f.jpg

So ..... this part of the carbs had to be replaced. Bought a used set of carbs and replaced it.

Given the opportunity i also cleaned thoroughly the carbs inside-out . Replaced also every o-ring, they where past their best and did not want to go through this again.

Carbs broken appart....

AXL_3575_resize_zpsd235e937.jpg

AXL_3581_resize_zpsde3deb82.jpg

AXL_3583_resize_zps6efaec12.jpg

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AXL_3589_resize_zps6d0fffc6.jpg

The result.....after putting them back together (and after replacing the broken part, of course).....

AXL_3919_resize_zpse88ae148.jpg

AXL_3918_resize_zps31a5c76e.jpg

AXL_3917_resize_zpsf35c7adc.jpg

AXL_3915_resize_zps6b1d9c4f.jpg

AXL_3913_resize_zps4a3e139a.jpg

AXL_3911_resize_zps7dadb16e.jpg

AXL_3908_resize_zps4c4d6097.jpg

I have done A LOT more on the bike such as cleaning the starter motor and replacing the brush as well as the o-rings and oil seals, i just did not take photos of these....which i have regretted.

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It looks.........like a 2013 RVF400!!!!!!!!!!!!!!!!!!!!!!!

I think I know just where to put this.........

Thanks Veefer!!! :beer:

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hhhmmm I do not see the pictures..... just boxes to say that "this person moved or deleted this image"??

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hhhmmm I do not see the pictures..... just boxes to say that "this person moved or deleted this image"??

All pictures are there....i can see them....if anyone else can't see them please confirm.

Don't know if there was a temporary problem with photobucket...

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They are back now :beer:

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Guest JeffLaurence

Absolutely beautiful work! I hope you have a big ugly dog sleep beside it at night!!

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Sa-weet! Beautiful bike. Thanks for sharing.

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Absolutely beautiful work! I hope you have a big ugly dog sleep beside it at night!!

Currently...he ....

AXL_4910_resize_zps3778e9ab.jpg

....is responsible for the bike..... :laughing6-hehe::laughing6-hehe:

...BUT don't be fooled by his innocent look, it can be deceiving,.....he has good and reliable friends....

depositphotos_2095255-Attack-of-rottweil

:laughing6-hehe::laughing6-hehe:

Edited by alexandervf

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Wow, very impressive, well done. And that NC35 looks great :fing02:

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Oh, and I have always hated how Honda uses real thin wire gauge for their harnesses, and hides crimped splices in the middle of the harness instead of using one whole piece of wire.

I would LOVE to rewire my bike, and use quality heavy gauge wire, but it would be 10 times the work of your carbed 400, due to the Fi and electronics.

I for one couldn't agree more....it's a pain in the a$$ but can you imagine the size and weight of the harness if every device on the bike had it's own wiring ??? !!! I do not find it to be all that wrong, it's just that the fabrication methods of the early 90's are poor to our 2013 eyes.

Indeed, if you were to start this project.... it would be MASSIVE as it is very expensive, but , you will also gain A LOT.

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Guest JeffLaurence

What is going to the centre of your rear wheel ? Speedo drive?

J

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What is going to the centre of your rear wheel ? Speedo drive?

J

Single nut wheel with retaining pin.

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Guest jcmcc89

Amazing work man.. definitely a labor of love

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