1990 Suzuki DR800 electrics
 

The electrics on the Suzuki DR800 failed today. The bike is 24 years old and some of the wires and plastic coating is getting brittle and I'll have to go through the wiring harness and replace parts of it. Any hints or advice before I start chopping and soldering

Thanks,

Shane

Hi Shane,


As a bike gets older what tends to happen is anywhere you start to bend the wiring loom to fix a section you will get a new break - especially if the wire has been subjected to direct sunlight. There will be areas close to the frame where the wiring wont be too bad, but constantly chasing wiring breaks is a real PITA - not to mention getting stranded constantly, you might do better to take the bike off the road and put in a new loom if you are intending to keep the bike for a while.


I believe this is the correct UK part no : 36610-31D00


If you choose to repair the loom, use good quality wire and heat shrink every solder joint - have about 2 inches of heat shrink each side of the join, good luck!

Wiring harness repair
 

Hi everyone,

I think I have finished cutting, soldering, crimping and heat shrinking . Fixed not only the fault on the pickup coil but a bunch of other frayed wires and insulation. It should be good to go. So the next step is to test and also put it all back together and make it look pretty.

My question is to ask you all for photos and ideas on where the cables should be routed. I have the stock manual and will go with that primarily but firstly it is a black and white drawing and photos will help. Secondly, I am open to ideas, such as using the TZ125R ignition barrel and leads. That was brilliant. Please paste up photos and ideas, I have time and want to make this a neat and easy to support job. Maybe get another 24 years out of the beast!