Wire harness repair/restoration

All to do with wiring, charging or just trying to figure out whats gone wrong.

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Roger486
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Re: Wire harness repair/restoration

Post by Roger486 »

Amazing! Great job! I just hope that I have a small amount of the patience required to get close.

By the way, what paint do you use for the black on the body.

Roger
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Roger

"One slowly evolving GT500A"
mnellis
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Re: Wire harness repair/restoration

Post by mnellis »

Thanks for the tutorial on your technique. Did the plastic caps for the switches come right off? I have a T500 and the turn signal switch plastic cap will not come off and I don't want to break it.
Mike Nellis

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Roger486
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Re: Wire harness repair/restoration

Post by Roger486 »

Once again, here are Suzsmokeyallan's (corrected) instructions in printable form...
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Last edited by Roger486 on Sat Jul 09, 2011 8:40 pm, edited 1 time in total.
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Roger

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Suzsmokeyallan
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Re: Wire harness repair/restoration

Post by Suzsmokeyallan »

Thanks for that Roger but you need to remove the paragraph above the first photo, the other type of switch knob I was referring to about the attachment types with the clips was related to the T500 and not the GT750.

I'm having a bit of an issue getting the wires in the grades and colours I need for my harness upgrades posted earlier in this thread, and after looking around southern Florida as well as on ebay, I had to end up ordering them on-line.
Two strokes, its just that simple.

69 Suz U70
69 Suz T500
72 Suz GT750 cafe
74 Suz TS250
74 Suz GTXVR project
75 Suz RE5
75 Suz GT750
76 Suz TS400
76 Suz GT750
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86 Suz RG500x2
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mnellis
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Re: Wire harness repair/restoration

Post by mnellis »

Roger486 wrote:Once again, here are Suzsmokeyallan's instructions in printable form...
Excellent, great job! Thanks.
Mike Nellis

CMRA #23 Expert
'75 T500
'68 Honda CL350
'70 Honda CB450
'75 Honda GL1000
'04 Suzuki GSXR 1000 (racebike)
'00 Yamaha YZ426
'01 Yamaha Raptor 660
'85 Honda 250 Big Red
RV-6 Kit Airplane
Roger486
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Re: Wire harness repair/restoration

Post by Roger486 »

Suzsmokeyallan wrote:Thanks for that Roger but you need to remove the paragraph above the first photo, the other type of switch knob I was referring to about the attachment types with the clips was related to the T500 and not the GT750.
Sorry about that... this should fix it... I thought that the information about removing the switches was useful, but I don't want to confuse people.

PS - I have managed to find RustOleaum spray paint in New Zealand... so I can have a go. Now I need to find someone who can bead blast.
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Roger

"One slowly evolving GT500A"
mnellis
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Re: Wire harness repair/restoration

Post by mnellis »

Suzsmokeyallan wrote: mnellis:
The GT switch sliders are screwed on with a small counter sunk screw thats still available from Suzuki BTW, while some other models use a push on slider.
These other types usually have a plastic shaft design that meshes with two tiny visible slots on one side of the switch slider.
If this is the type you have you need to lift the slider evenly at the front and back while tilting it slightly to a side away from the slots so the little wedges on the shaft can slip past the slotted holes in the slider.
Why not send me a photo and let me confirm which ones you have on your bike.
Thanks for the offer to look at my switch, here is a picture. It looks like the previous owner pushed the plastic on two far and it has rubber the housing. Or, he may have the wrong slider on there and needed to grind part of the housing away to get it to work, I'm not sure. My plan was to use some JB Weld to build up the area before finishing it off with the paint method you posted.

Image
Mike Nellis

CMRA #23 Expert
'75 T500
'68 Honda CL350
'70 Honda CB450
'75 Honda GL1000
'04 Suzuki GSXR 1000 (racebike)
'00 Yamaha YZ426
'01 Yamaha Raptor 660
'85 Honda 250 Big Red
RV-6 Kit Airplane
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Suzsmokeyallan
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Re: Wire harness repair/restoration

Post by Suzsmokeyallan »

See a photo is important, I thought you were talking about the light switch sliders when you're talking about the indicator switch slider. If it has no screw underneath it, its made on to the metal bar and you have to undo the bar itself from inside the housing and slide it out through the front of the switch.
For the rubbing issue repair the sections and make it smooth, then get a piece of thin clear plastic like the type you find in new shirt collars to stiffen them for presentation.
Cut a piece of the plastic sheet the same size as the knob with a slot to pass over the bar to fit between the knob and the switch housing. This extra piece now acts like a self lubing slider so the knob itself does not dig into the housing.
Two strokes, its just that simple.

69 Suz U70
69 Suz T500
72 Suz GT750 cafe
74 Suz TS250
74 Suz GTXVR project
75 Suz RE5
75 Suz GT750
76 Suz TS400
76 Suz GT750
81 Suz GSX1100
86 Suz RG500x2
88 Hon CR500
93 Hon CBR900RR
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mnellis
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Re: Wire harness repair/restoration

Post by mnellis »

Suzsmokeyallan wrote:See a photo is important, I thought you were talking about the light switch sliders when you're talking about the indicator switch slider. If it has no screw underneath it, its made on to the metal bar and you have to undo the bar itself from inside the housing and slide it out through the front of the switch.
For the rubbing issue repair the sections and make it smooth, then get a piece of thin clear plastic like the type you find in new shirt collars to stiffen them for presentation.
Cut a piece of the plastic sheet the same size as the knob with a slot to pass over the bar to fit between the knob and the switch housing. This extra piece now acts like a self lubing slider so the knob itself does not dig into the housing.
Good idea with the plastic sheet, thanks.
Mike Nellis

CMRA #23 Expert
'75 T500
'68 Honda CL350
'70 Honda CB450
'75 Honda GL1000
'04 Suzuki GSXR 1000 (racebike)
'00 Yamaha YZ426
'01 Yamaha Raptor 660
'85 Honda 250 Big Red
RV-6 Kit Airplane
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tz375
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Re: Wire harness repair/restoration

Post by tz375 »

Suzsmokeyallan wrote:See a photo is important, I thought you were talking about the light switch sliders when you're talking about the indicator switch slider. If it has no screw underneath it, its made on to the metal bar and you have to undo the bar itself from inside the housing and slide it out through the front of the switch.
For the rubbing issue repair the sections and make it smooth, then get a piece of thin clear plastic like the type you find in new shirt collars to stiffen them for presentation.
Cut a piece of the plastic sheet the same size as the knob with a slot to pass over the bar to fit between the knob and the switch housing. This extra piece now acts like a self lubing slider so the knob itself does not dig into the housing.
That sounds like a great idea.
Roger486
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Re: Wire harness repair/restoration

Post by Roger486 »

Suzsmokeyallan wrote:Roger can you add these images into the PDF file on the switches you have created so it helps with illustrations.
Here you go. Simple instructions to follow!
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Roger

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Suzsmokeyallan
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Re: Wire harness repair/restoration

Post by Suzsmokeyallan »

That pdf file update looks great Roger and the extra images give a better idea of the visual restoration process.
Two strokes, its just that simple.

69 Suz U70
69 Suz T500
72 Suz GT750 cafe
74 Suz TS250
74 Suz GTXVR project
75 Suz RE5
75 Suz GT750
76 Suz TS400
76 Suz GT750
81 Suz GSX1100
86 Suz RG500x2
88 Hon CR500
93 Hon CBR900RR
98 Suz GSF1200x3
15 Kaw Ninja H2
Roger486
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Re: Wire harness repair/restoration

Post by Roger486 »

It makes me think that I could even have a go myself!! :lol:
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Roger

"One slowly evolving GT500A"
Roger486
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Re: Wire harness repair/restoration

Post by Roger486 »

Do you paint the insides of the switch bodies as well?
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Roger

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Suzsmokeyallan
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Re: Wire harness repair/restoration

Post by Suzsmokeyallan »

The interior gets painted during the process, but not intentionally. I'm more concerned about getting the edges and the overlap sections of the castings covered properly.
Too much paint on the interior could stop the parts from sliding back into their slots, so two light coats just to hide the raw aluminum finish would be perfect.
Two strokes, its just that simple.

69 Suz U70
69 Suz T500
72 Suz GT750 cafe
74 Suz TS250
74 Suz GTXVR project
75 Suz RE5
75 Suz GT750
76 Suz TS400
76 Suz GT750
81 Suz GSX1100
86 Suz RG500x2
88 Hon CR500
93 Hon CBR900RR
98 Suz GSF1200x3
15 Kaw Ninja H2
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