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Thread: Any Interest? - Wire Harness Reproduction

  1. #1
    Join Date
    Apr 2012
    Location
    MI, USA
    --
    3,199

    Any Interest? - Wire Harness Reproduction

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

    ________________________________________________

    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!
    Last edited by ps2fixer; 03-22-2018 at 05:54 PM.

  2. #2
    Join Date
    Dec 2011
    Location
    Grand Rapids, MI.
    --
    677
    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.
    1986 KLT 185
    1984 200S

    Feedback Thread: http://www.3wheelerworld.com/showthr...k-for-Ebaccm26

  3. #3
    Join Date
    Apr 2012
    Location
    MI, USA
    --
    3,199
    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....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!
    Last edited by ps2fixer; 06-17-2015 at 12:48 PM.

  4. #4
    Join Date
    May 2010
    Location
    Wichita, Kansas
    --
    1,354
    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.
    I just wanna go fast. If your not first, your last!!
    Reproducing the Tecate CDI. Contact me if you need one. I'm most accessible on FaceBook. You can find me on the 1984-1987 Kawasaki Tecate KXT250 Group.

  5. #5
    Join Date
    Apr 2012
    Location
    MI, USA
    --
    3,199
    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.
    Attached Thumbnails Attached Thumbnails 20140824_175432-resized.jpg  

  6. #6
    Join Date
    Oct 2012
    Location
    Lengby, Minnesota
    --
    492
    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!!!
    1983 ATC 200x
    1982 ATC 250R X2
    1983 ATC 250R : Future build
    1984 ATC 250R
    1985 ATC 250R : Main rider
    1985 ATC 363R Duner
    1985 ATC 250R : Future build
    1985 ATC 110
    1986 ATC 250ES : Future build
    1984 Tri Zinger
    2000 CR250R

  7. #7
    Join Date
    Apr 2012
    Location
    MI, USA
    --
    3,199
    Quote Originally Posted by hatc200x1 View Post
    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!
    Last edited by ps2fixer; 08-24-2014 at 09:48 PM.

  8. #8
    Join Date
    Apr 2012
    Location
    MI, USA
    --
    3,199
    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?

  9. #9
    Join Date
    Feb 2013
    Location
    Brazil, Indiana
    --
    663
    Quote Originally Posted by ps2fixer View Post
    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.
    Click image for larger version. 

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    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
    1979 ATC110
    1983 ATC110
    1984 ATC110
    1984 ATC125M
    1985 ATC110 2 of them
    1985 ATC110 The wife's
    1987 ATC125M
    1985 ATC250ES
    1984 DX225 with 250 timberwolf engine and swingarm. Wolf in DX clothing

  10. #10
    Join Date
    Apr 2012
    Location
    MI, USA
    --
    3,199
    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.

  11. #11
    Join Date
    Feb 2013
    Location
    Brazil, Indiana
    --
    663
    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...
    1979 ATC110
    1983 ATC110
    1984 ATC110
    1984 ATC125M
    1985 ATC110 2 of them
    1985 ATC110 The wife's
    1987 ATC125M
    1985 ATC250ES
    1984 DX225 with 250 timberwolf engine and swingarm. Wolf in DX clothing

  12. #12
    Join Date
    Oct 2002
    Location
    Northeast
    --
    16,937
    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.....
    WHO IS Q?? WWG1WGA!!


    86 ATC200X Flatrack ( I may not be fast but this is one FAST 200X!!

    86 ATC350X Motocross, 86 ATC452X Flatrack!!

    07 Weekend Warrior Toy Hauler

  13. #13
    Join Date
    Apr 2012
    Location
    MI, USA
    --
    3,199
    Quote Originally Posted by Dirtcrasher View Post
    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.


    Quote Originally Posted by Trike_crazy View Post
    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.

  14. #14
    Join Date
    Apr 2012
    Location
    MI, USA
    --
    3,199
    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.

  15. #15
    Join Date
    Apr 2002
    Location
    s.w. michigan
    --
    6,500
    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

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