wiring advice needed

[Texarican]

Some previous owner of my 96e really did a number on the wiring.  In fact, it was just comical to see so I bought a full harness and started installing yesterday.  Everything went well and I've got factory connectors all the way up to the light bucket.  That is where the potential jumble starts over.

I've got a new right hand control assembly with factory connector so no worries there.  The factory connector was cut off of the left hand controls so I either have to buy another assembly (not preferred at this point) or I guess cut the factory connector off of my new wiring harness and connect all wires individually.  Same is true of the ignition wires and meter wires. 

I really hate cutting the factory connectors off my wiring harness.  Plus, I'd like a connector method that allows for easier tear down should it be needed and all of this needs to cram into the headlight bucket.  Any suggestions? 

[Texarican]

Well, no replies and I'm itching to get this bike running so here is what I've decided to do.  I need two 9 position and one 6 position connector as I recall.  Radio Shack in my neighborhood has interlocking connectors in stock.  The goal is to have something that can be pulled apart if needed.  Guessing I'll have to put on both the male and female ends but it sure would be cool if I get home with them and find out I have a match to the factory connectors. 

[tucsondog]

Greetings and salutations!

First off, the only wiring ive done on a bike is making quick disconnects for my front signal lights.
However... I have rewired my truck, so i have an idea of what you're going through (25+ years of road salt and farm use will "do things")

Back to the bike though... as far as cutting up your factory harness, go for it. Although take the time to label everything you cut, having to go through with a multimeter later on really sucks. Just be sure that when you do cut the wires, leave at least 2-3" to work with. When making the connections, I like to slip on about 1" of heat shrink tubing over one wire, join the two with a crimping connector and then slide the tubing over the connector and break out the hair-dryer for a permanent, watertight seal.

As far as the quick disconnects, just be sure the ones you get can handle the gauge of wire you'll be using, otherwise there is the potential of fire.
http://www.radioshack.com/product/index.jsp?productId=2104009
These would work fine.

After you make all the connections, and you are 110% sure that all the wires/pins are in the correct place, and you've tested everything a dozen times, hot-glue the backside of the quick-disconnects so there is no chance of moisture getting in and corroding the wires from the inside.

Good luck, and post some pics when you're done!

[Texarican]

Thanks.  Those were the exact connectors I was looking at!

[tucsondog]

Oh, and as far as cramming things in and getting everything to stay put, Zip-Ties!!! Just be sure that you have enough slack so you can turn lock-to-lock without ripping apart any connection. Electrical work isn't that hard, you just have to be willing to take the time to do it right. Plan it, measure it, measure it, measure it, cut it, label it, connect it, secure it, ride it!!!

[The Buddha]

Oh yea that famous ratshack trash ... also look @ mikesxs for equivalent rectangular trash ... your best bet IMHO is cutting them off jap cars @ pull a part ... BTW dont look @ me funny ... I only cut em off stuff like doors and other crap where someone hacked it already and took the door off. I Just hack 3 inches inside the first hack.
Cool.
Buddha.

[starwalt]

Don't cut the original..I would reconsider asking on the want-to-buy section for the electric parts you need before using the 'molex' style connectors.
Those connectors are designed to lock into a square hole in a chassis.
Chances are there are plenty of Suz spares in our community (I am part of that community - a photo would help).

Our Buddy Buddha does have a point if you have a good bone yard nearby.
I suspect rather you want to put this bike a near original as you can.

Of course the electricity doesn't know the difference...unless you do a bad job.

Be aware that some years have different clutch switches and other items as time and suppliers changed.

[sledge]

Hello Doug