Electrical Harness

[copeland3300]

So I was looking over my wiring harness, and I felt like some of the connections were iffy as to their reliability.

Keep in mind, this is for an XS that I'm rebuilding, so it's not as though everything is working well and I'm just tinkering for the sake of it.

Having said all that, what connectors and/or wiring would you all recommend? I did some searches, but I wasn't able to locate a kit that had a multitude of different plugs. Given that not everything is 2, 4 or 6 pin connectors, having a bunch of different ones would be useful as I have to replace them.

Thanks!

[DGXSER]

Look up Oregon Motorcycle Parts "Geezer" aka... Tony sells most if not all the connectors for these bikes. I would think you could discuss it with him and get a package setup.

[crazy steve]

If you're looking for a 'kit' that covers everything you need, forget it. There are kits out there, but few that will have everything you need (and extras you won't) and they're expensive to boot.

http://www.oregonmotorcycleparts.com/connectors.html
These are the ones DGXSER is talking about, and are basically the same as OEM. If price is a consideration, probably your best choice.

http://www.wirecare.com/deutsch-conn...r=12&Series=DT
If you're willing to spend more, these are a definite upgrade. Fully sealed and available in different amp ratings, these are a bit bulkier but easier to work with after installation. My personal choice for the prone-to-failure alternator connections on the XS when they need replacing...

Keep in mind that any quality connector will need a dedicated crimper designed for that termination. The Deutsch crimper is horribly expensive, but low-cost knock-offs are available on eBay (about $35 last time I checked). You also won't find all the right 'combinations' in plugs, so you may have to use some with 'left over' wire connections or multiple plugs. There's a few other brands out there (Amp/Tyco is one) but those can be harder to find.

[IanDMacDonald]

I have great experience with vintageconnections.com. With regard to replacing the connectors and you are not going to go with Molex connectors, I would definitely recommend GM weatherpak connectors. If you are replacing your bullet connectors with bullets, make sure you get the open-barrel crimpers. You can also swap everything out with weather resistant spade connectors from any auto store. You will not find those bullet connectors in any store!!!

[copeland3300]

Hmmm,

Well you all have given me a good bit to think about.

Thanks for all the info!

[copeland3300]

So are the molex ones literally what's used in computers?

I like the weatherpak connectors a lot. I might go with those as needed.

[IanDMacDonald]

^ Yes, that is one application for them. Molex connectors are used worldwide for thousands of applications. I have them on one of my Suzuki GS's. The weatherpak connectors are not cheap by any means, but, absolutely worth it in my opinion.