Custom built wiring harness? - Honda Rebel Forum
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post #1 of 39 Old 11-30-2010, 10:43 PM Thread Starter
 
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Custom built wiring harness?

Planning on hardtailing my Rebel over the winter and want to build a wiring harness for it. I want to trash everything except headlight, taillight, and engine electrical.

Was thinking of building my own harness so I can get rid of the everything else, anyone else done it?

Are the rebel's pretty easy to rewire?
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post #2 of 39 Old 12-01-2010, 03:28 AM
 
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Here ya go. just need to figure what you want to keep.

http://www.hondarebelforum.com/f36/h...iagram-83.html

http://www.hondarebelforum.com/f36/h...gram-1107.html

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post #3 of 39 Old 12-01-2010, 03:48 AM
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Here's the second generation 250 wiring diagram, courtesy of 88nightrider.





1987 CMX250C Rebel
2002 FSC600 SilverWing
1983 Yamaha Midnight Virago XV920MK
Put your bike's year and size in your signature.
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post #4 of 39 Old 12-01-2010, 04:14 AM
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I threw a copy of that second gen diagram up in the FAQs.




1987 CMX250C Rebel
2002 FSC600 SilverWing
1983 Yamaha Midnight Virago XV920MK
Put your bike's year and size in your signature.
It helps others help you.

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post #5 of 39 Old 12-01-2010, 07:40 AM Thread Starter
 
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Good deal. I figured it would be fairly simple, just wanted to get a few others opinions.

Thanks

86 CMX450C- Under Construction
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post #6 of 39 Old 12-01-2010, 01:57 PM
 
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I built many a wiring harness for vehicles and boats over the years. The thing to remember is keep the female bullet recepticles closest to the "hot" side of the wiring. I recommend using the heavily shielded waterproof type you can get at most auto parts stores. Lowes and home supply stores also carry a lot of connectors in bulk packs for bigger jobs at a much bigger savings. Use a proffessional style crimp tool and the proper size connectors for the best results. Don't use cheap wire, you'll regret it later. Marine grade wiring would be the best option, its usually tinned to prevent corrosion. If you have a marine salvage yard nearby you can usually get a huge amount of wiring in different gauges as well as split type wire wrap from a boat wiring harness cheap. Good luck on your project! Regards, Chef

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post #7 of 39 Old 12-01-2010, 03:14 PM
 
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Only thing I would add is to solder all connectors. You then have the insurance of knowing it wont come apart .

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post #8 of 39 Old 12-01-2010, 07:21 PM Thread Starter
 
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Thanks guys, I was thinking of actually trying to keep the original harness, just thin it out.

Not sure if that's possible or not.

Also, I plan on eliminating the bullet connectors and just do one peice runs of wire.

86 CMX450C- Under Construction
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post #9 of 39 Old 12-01-2010, 08:38 PM
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You will need some connectors.




1987 CMX250C Rebel
2002 FSC600 SilverWing
1983 Yamaha Midnight Virago XV920MK
Put your bike's year and size in your signature.
It helps others help you.

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post #10 of 39 Old 12-02-2010, 01:43 AM
 
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I took and and customized the wiring harness for the tail end of the Rebel and the whole thing from one of my Guzzi's. I used wire that was one gauge thicker than stock. Solder and shrink tube. And I kept the wire color true to stock.


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