Could anyone help with wiring problem?

[Martynbiker]

I am in need of a new loom for an XT600 2KF 1987 model
part number is 2KF-82590-00 but it is DISCONTINUED Yamaha part.

Has anyone any experience of making a loom from scratch?
pitfalls?
Tips? Hints?
any help will be appreciated....... I havent a clue where to start, it all seems so daunting. I have tackled everything else on the bike, but this has me worried.

also if anyone has a COLOUR wiring diagram they could email me, or pictures of a wiring diagram my email is martynbiker@gmail.com

thanks

Martyn

[danward79]

I have made loads of looms up for various jobs.

One thing I would say is if you can use the original as a template it would be a great help, as this will give you the lengths you are going to need, an inch +/- can be a pain either way.

[yhprum]

Martyn You might still want to get a harness from a wrecker. You'll be without your bike for awhile, whist you make up a new harness.
All the plastic bitsconnectors and will have to be sourced or cleaned up. Lay the original/spare harness out on a sheet of plywood, pull the ends straight and use some brads for your points to keep it all organized. Then, run the wiresone at a a time until youre done. Then wrap it all up.There are tools you can use to release the terninals from most tyres of the plastic connector blocks, unless they are glued in. I'm not sure about XT connectors.

Good Luck! Steve

[Martynbiker]

Hiya dan....... its not so much the loom in itself thats worrying me. its the connectors! I dont want to have to solder every joint and have NO connectors. I also dont want to have the situation where i am cutting the old block connectors off the loom and re using them as then there will be MORE joins to go wrong.
If I make a loom up with solder on bullet connectors instead of the plastic block connectors, once the insulation to the connectors it is going to be a lot bulkier than the Original Manufacturers Item... and as it is the Original loom has to be shoehorned behind the headlamp unit!!

so what to do?

I have thought about carrying a very powerful rechargeable torch about and using a cyclists LED rear light for if I have an emergency at night and just blagg my way if I am stopped by the police....( chances are they wont speak much english here in Inland Spain so I may get away with it) but it doesnt solve the problem....

I would prefer a NEW loom, I cant believe there isnt one available anywhere in the world.......... but im running out of ideas, money and hope...

Martyn

[Martynbiker]

Thanks Steve, that seems like my only option at the moment........... what a nightmare!!!!!!!!!!!!!!!!