The Rebirth Of An Rvf400 Wire Harness....

Hi to everyone once more.........

As the title states,

i decided about a year ago, after facing a few (Critical) electrical problems to build ,reconstruct,revive ... you choose the word that suits best, the whole wiring harness.

The wire used for the job was a high grade teflon coated wire with silver plated strands bought from the US. The connectors are new type, splash proof, sumitomo's and furukawa's from Japan.

I have also rewound my stator, made new spark plug wires installed the (rare to us here) ER9EH IX spark plugs and replaced almost every incandescent bulb with leds. A volt meter has been installed as well.

There were a few more jobs done as well which i will show you ..... So....

These are spools that were used (there are more, they were on pending orders)....

[image: AXL_4661_zps6a6b3057.jpg]

Here you can see the spark plug wires.....

[image: AXL_4663_zps4d0a8ed4.jpg]

I had to... lets say... "modify" some older spark plug wires in order to "extract" the part that i needed...

[image: AXL_4662_zps538d5fb9.jpg]

In the following photos, you will see the connectors used for the harness....

[image: AXL_4635_zps6370e203.jpg]

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[image: AXL_4629_zps3c9dfe00.jpg]

[image: AXL_4628_zps90e4372e.jpg]

The following photos show the beginning of the harness build....

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[image: AXL_4683_zps8d4d6d7d.jpg]

[image: AXL_4684_zpseb35dc40.jpg]

Smaller clocks loom...(did not mess with the T10 rubber bases, could not find them anywhere on the internet as a oem part)....

[image: AXL_4660_zps1b11833d.jpg]

Side stand switch.....

[image: AXL_4659_zpse79e8dfb.jpg]

Main keyswitch / ignition....

[image: AXL_4658_zps9368fbd9.jpg]

Tail light loom....

[image: AXL_4657_zps598a91ce.jpg]

Left hand side switchgear......

[image: AXL_4678_zps4752352c.jpg]

[image: AXL_4675_zpse3d0d484.jpg]

The Left hand side switchgear was later replaced by a cbr900 left hand side switchgear such as this one.....

[image: L-Hswitchgearcbr900.jpg]

The right hand switchgear.....

[image: AXL_4656_zps96a42b29.jpg]

....Which was later replaced by a CBR600 right hand switchgear such as this one.....

[image: Killswitch2cbr60007.jpg]

As i said above.....leds almost everywhere....

The clocks....

[image: AXL_4701_zps326bc551.jpg]

[image: AXL_4702_zps5f58ecf5.jpg]

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[image: AXL_4698_zps25f533d3.jpg]

[image: AXL_4696_zps03224d90.jpg]

.....And the tail light unit....

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.....Testing of the tail light...

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The stator.....a painful job...but very rewarding if done right.

Here is what it looked like before i messed with it......

[image: AXL_4727_zps472f1bb2.jpg]

[image: AXL_4725_zps26390b97.jpg]

The core...cleaned...

[image: AXL_4736_zps6c02c9c3.jpg]

[image: AXL_4738_zps89106147.jpg]

Preparations for the rewiring of the core....

[image: AXL_4772_zps4cf95f67.jpg]

The stator....FINALY....ready to be submerged in the special resin...

[image: AXL_4774_zps5cff1902.jpg]

[image: AXL_4775_zpsfbc5a1b1.jpg]

Submerging the stator in the resin...

[image: AXL_4781_zps1439cce0.jpg]

[image: AXL_4780_zpsba3eb7f7.jpg]

The stator...ready for installation...

[image: AXL_4794_zpsa9012765.jpg]

[image: AXL_4793_zpse331aefe.jpg]

The volt meter .......

[image: Voltmeter1_zps385033c1.jpg]

[image: AXL_4846_resize.jpg]

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[image: AXL_4844_zps6f0c375a.jpg]

Thermo-switch / sensor, so that it triggers the cooling fan when the R/R reaches 46 degrees Celsius .....

[image: AXL_4720_zps10003e22.jpg]

[image: AXL_4718_zps1db93009.jpg]

[image: AXL_4714_zpsf9abe488.jpg]

Other mods....

Hand made R/R stainless steel base...

[image: AXL_3964_resize.jpg]

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Relocating the R/R under the pillion seat ....

[image: AXL_3971_resize.jpg]

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Hand made stainless steel V-piece mesh....

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Top radiator hand made stainless steel mesh (front and rear of the rad).....

[image: AXL_3882_resize.jpg]

[image: AXL_3881_resize.jpg]

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TIP: Some of you may already know it , some of you may not. If you are about to mess with teflon coated wires they do not strip the usual way.....You will need a special tool for striping teflon wire insulation.

If you do not have the money for such a tool (I did not) you can make it like i did....you will have to brake down one of these....

[image: AXL_4771_zps2c0d43b8.jpg]

and make something like this....

[image: AXL_4766_zpsef4aeef2.jpg]

This was a job that took almost a year to complete. It was a painful job (especially the stator) but i very much enjoyed it because i LEARNED A LOT.

Thanks for reading.

Wow, fantastic! That's some impressive work. :fing02:

:cool:

Wow! Persistence, ingenuity, and beautiful work. Thanks for sharing!

WOW! Just... WOW!!!

You sir, are the most patient man in the universe.

How about a few beauty shots of your 400 from afar?

Oh, and I have always hated how Honda uses real thin wire gauge for their harnesses, and hides crimped splices in the middle of the harness instead of using one whole piece of wire.

I would LOVE to rewire my bike, and use quality heavy gauge wire, but it would be 10 times the work of your carbed 400, due to the Fi and electronics.

Outstanding. Nicely done! :fing02: If the rest of the bike is anything as nice as the wiring, it's beautiful. Thanks for all the pics - we'd love to see more!

Here are a few shots of how my bike looks today.....

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I have also done the carbs.... pics will follow....soon....

Wow! Bike looks amazing!

Thanks everyone for your kind words!!

It looks.........like a 2013 RVF400!!!!!!!!!!!!!!!!!!!!!!!

I think I know just where to put this.........

[image: AXL 4881 resize zps7209a09e]

Due to the fact that i had plenty of time waiting for the spools to arrive, i said, why don't i give a good clean treatment to my carbs....what do i have to lose???

Yes right.....Take a look what i found .....The "No brain left" "Neanderthal" mechanic that i trusted him with my bike had a "faster" way in his mind of removing the carbs from the bike, obviously, he hit them from underneath.....The result a good size crack....

[image: AXL_3577a_zps2f999c3f.jpg]

So ..... this part of the carbs had to be replaced. Bought a used set of carbs and replaced it.

Given the opportunity i also cleaned thoroughly the carbs inside-out . Replaced also every o-ring, they where past their best and did not want to go through this again.

Carbs broken appart....

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The result.....after putting them back together (and after replacing the broken part, of course).....

[image: AXL_3919_resize_zpse88ae148.jpg]

[image: AXL_3918_resize_zps31a5c76e.jpg]

[image: AXL_3917_resize_zpsf35c7adc.jpg]

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I have done A LOT more on the bike such as cleaning the starter motor and replacing the brush as well as the o-rings and oil seals, i just did not take photos of these....which i have regretted.

Veefer800Canuck

It looks.........like a 2013 RVF400!!!!!!!!!!!!!!!!!!!!!!!

I think I know just where to put this.........

Thanks Veefer!!! :beer:

hhhmmm I do not see the pictures..... just boxes to say that "this person moved or deleted this image"??

Dutchy

hhhmmm I do not see the pictures..... just boxes to say that "this person moved or deleted this image"??

All pictures are there....i can see them....if anyone else can't see them please confirm.

Don't know if there was a temporary problem with photobucket...

I can see the pictures just fine. All of them.

They are back now :beer:

Dutchy

They are back now :beer:

:beer: :beer: :beer:

Absolutely beautiful work! I hope you have a big ugly dog sleep beside it at night!!

Sa-weet! Beautiful bike. Thanks for sharing.

JeffLaurence

Absolutely beautiful work! I hope you have a big ugly dog sleep beside it at night!!

Currently...he ....

[image: AXL_4910_resize_zps3778e9ab.jpg]

....is responsible for the bike..... :laughing6-hehe: :laughing6-hehe:

...BUT don't be fooled by his innocent look, it can be deceiving,.....he has good and reliable friends....

[image: depositphotos_2095255-Attack-of-rottweil]

:laughing6-hehe: :laughing6-hehe:

Wow, very impressive, well done. And that NC35 looks great :fing02:

Veefer800Canuck

Oh, and I have always hated how Honda uses real thin wire gauge for their harnesses, and hides crimped splices in the middle of the harness instead of using one whole piece of wire.

I would LOVE to rewire my bike, and use quality heavy gauge wire, but it would be 10 times the work of your carbed 400, due to the Fi and electronics.

I for one couldn't agree more....it's a pain in the a$$ but can you imagine the size and weight of the harness if every device on the bike had it's own wiring ??? !!! I do not find it to be all that wrong, it's just that the fabrication methods of the early 90's are poor to our 2013 eyes.

Indeed, if you were to start this project.... it would be MASSIVE as it is very expensive, but , you will also gain A LOT.

What is going to the centre of your rear wheel ? Speedo drive?

J

JeffLaurence

What is going to the centre of your rear wheel ? Speedo drive?

J

Single nut wheel with retaining pin.

Amazing work man.. definitely a labor of love