Good to hear you're close!

What have you used this harness for, before this project?

I swear next project I do involving electrics I will just make a custom harness... dealing with all the excess wires in a stock harness sends me bat shaZam!... I feel your pain Rich 

Menno, I've been changing this harness since I got this bike... 7 years ago? This is the second time it's been completely chopped up though. Pete, I seriously considered that for this time. But you still have to fit all the connectors (and new connectors aren't cheap!).

Brake pads came in today, so I'm rebuilding calipers.....

Very true Rich, connectors aren't cheap at all, although going custom means you can eliminate some of the excess wiring and potentially reduce the number of connectors and the number of pins required for them also, but still... a fair amount of thought and planning is required.

Good news on the brake pads, she'll be a proper roller before you know it!

So.... I've been holding off on the wiring for a couple days for a couple reasons. First, I'm waiting for an ignition switch from eBay and I'm also searching locally for a 5 pin relay. Since the brake pads came in I turned my attention to them. The good news? The front brakes are kinda done..... I was bleeding them and ended up with a good bit of resistance. I did pop all the pistons out, cleaned the seals (wipers), etc, etc. as well. Now the thing that bugs me is that iI'mnot getting a "great" feeling from the front brakes. It almost feels like there is air in the system although no air is coming from the bleeder valve. Maybe my brake fluid is contaminated? Shouldn't be.... but it is possible. So I'll be keeping am eye on that.

Now the bad news. I struggled for HOURS to bleed the rear brake. Tried everything - getting the caliper lower than the master cylinder, using a vacuum to suck air from the bleeder valve, etc... No matter what I did though I couldn't get brake fluid to flow from the reservoir. Low and behold.... the master cylinder isn't building enough pressure! Bastard. Must have a bad seal around the piston or something. Luckily, another Busa cylinder is about $9 on ebay.

Oh, and photobucket is under maintenance, so I'll be posting pics later.

Photobucket is working again - here's the 6 pots ready to go:



Tonight is my "working night" so I should have some more progress tomorrow. ...

Ok. I ordered a Katana / Bandit ignition switch since the stock switch ddidn't stand a chance of working. But because of my fairing mount I had to modify the upper clamp for everything to clear. So much for the powder coating...



Ignition switch clears everything now. Still need to notch out the lock material on the frame, but I'll get that later.

At the beginning of the night, all the wiring for the front end was hanging down like this:



Shortened and connected the wires for the ignition switch, right hand control, and left hand control (no wire looming until EVERYTHING is wired up and tested - no worries):

Last one for the day. Connected wires for the headlight, front signals, and signal relay. Both signals are lit up because I hit the hazard button on the GSXR control.... and they do flash on and off.



I actually ran out of heat shrink tubing (again) so I couldn't finish up the wiring for the rear end or the digital speedo.

Nice work as always Rich! Glad to see that spaghetti starting to take some form too.

That ignition switch seems very neat in there, like it belongs there. Good stuff!!

Thanks Pete!

I'm waiting for a couple connectors from MikesXS.com  (pretty good prices if anybody is looking for electrical connections) so that will take a day or two. But my replacement Hayabusa MC showed up today. Happy to say it only took a few hours of swearing to get that straightened out....still in the process of bleeding the front and rear brakes too.

Little update this week. I had fork oil leaking on my GS450 so that was a priority.... and then I had a couple days of really nice riding weather..... so not too much accomplished on the GR. Here are the wiring connectors from MikesXS.com :



The 4 pin connector is for the rear lighting so I have a clean & quick disconnect for removing the seat frame. The 9 pin is for an Acewell digital speedo.....which I changed my mind on using. I found a Chinese speedo that has a fuel gauge & gear indicator, so that's in the mail now....

Messing with the wiring some more last night. I was testing the connection on a 5 pin relay and I discovered I needed to change the constant + connection to the relay. It wasn't a switched power source, so my fog light was on all the time if the high beam was off, including when the ignition switch was turned off! But here's a pic of the low beam headlight w/ fog light illuminated :



And when I flip the high beam on, the fog lights turns off and the flashlight of God turns on......



Seriously, that thing is blinding. You can see it confused the camera on my phone by the little triangle of greenish lights off the side.

Wow that's some serious light Rich!!!

Thanks Pete! If they were any brighter, they would light up the road for you when I turn them on..... haha.

New back tire came in today:



Pilot Road 3, 150/70ZR-17. Hopefully get it mounted tomorrow.

Flashlight of GOD hahaha I love it!!!  Those 3 green dots too wow that made me laugh    WOO for the weather we had for the weekend indeed, finally felt like summer!!!

That is such an awesome looking tire... I wanted that one when I needed a new one for my GS but I went with the Activ instead... I wish I would have gotten that one the more I think about it (so I try not to lol) 

Yes I like the flashlight reference too!

A buddy with a gixxer  litre bike has his low beam adjusted a few turns too high. .. and a brighter than standard bulb also..

Riding in front of him in the evenings is difficult... often refer to it as Endless Sunrise Behind Me. ..

But flashlight of God is more succinct..

Well, my schedule for work has me flipped upside down at the moment.... usually I'm on steady midnight so my last night off I stay up late working in the garage. Now I have to work daylight shift so my shop time is practically nonexistent. Boo...... but here is the new tire on the wheel, all mounted up to the bike:



And I ordered some 60mm silicone tubing to be used for an air filter mount / extension:

That makes here a real roller now Rich, very nice!!

What's the plan to make use of the silicon?

Holy crap that picture is huge..... sorry. The back bone of the frame is right behind the carbs, so to mount an air filter I need to space it away from the carbs. I used rubber tubing before, but figured silicone was more appropriate.

Later this week I'll definitely be ordering the matching front tire, along with some other small bits. And once my digital speedo comes off the slow boat, I should be able to finally finish the wiring.