Rear Wiring Harness Replacement

[Sambeaux]

99 Std

I recently discovered that when signaling for a turn both right and left indicators were flashing (rear only – front works normally).   In sorting this out, I discovered that the previous owner had re-wired the rear wiring harness.  It appears that the harnesses were damaged near the top of the fender where the two sections are bolted together.  This "bear's nest" of red and black wires seems to be the issue as several wires had chafed and connections had lost their tape wrappings.  Lots of bear copper showing.

I have ordered replacements  but haven’t quite sorted out how the harnesses are mounted under the fender.   I haven't pulled the rear wheel yet, but there seems to be some type of conduit molded into the underside of the fender at the top.  On the lower section of the fender - the wires were tie wraped and ducted taped to the underside of the fender (This don't seem quite right).

If anyone has “been there and done that”, I would appreciate any hints on the removal / replacement and how to better secure the lower portion of the harness.

Thanks

Sambeaux

 

[Pete]

Just did one last week, Supervalk conversion.

To make it easy, remove the read section of the fender for ease of access.
In removing the rear of the fender 3 hands are helpful, as you must remove the screws/bolts, hold the fender and unplug the connection.
 
The channel must be bent open, I use my fingers to gently open it from the open side. Only as far as needed to remove or insert the cable.
Because of the large multi connector the front harness removes from the rear and the rear harness removes from the front.

The front harness connections are under the right side cover, the rear harness connections are in the tail light and turn signals. All are color coded so follow the color codes in making all connections.
If in doubt refer to the wiring diagrams. In the turn signals here are 3 ground connections, Try to connect them back as they came apart, although a ground is a ground and it should not matter.

The front harness is fairly easy, just note the placement of the two rubber grommets during removal. Slide them on the harness as you thread it thru and then push the grommets into the fender holes last after positioning the harness. Be aware sometimes a grommet will be missing, there should be one everywhere wire passes thru the fender or a support tab.

The rear harness replacement requires removing the tail light and turn signals for access to the individual plugs.  Note the placement of the grommets, and insert into the fender after positioning the harness. The hardest part here after replugging the tail light and turn signals is getting them remounted with the rubber gaskets positioned correctly. You just have to work with it until the housing is correctly seated into the rubber molded gasket and edge of the rubber is seated outside the housing. A toothpick can help move it out if trapped under the housing.

It can also be a little difficult getting the plugs and wires folded into the housing so they will not get trapped between the fender and the housing. A trapped wire could penetrate the covering and short against the fender, so be careful.

Before remounting the rear fender section carefully bend the channels to hold the cables, again I just use my hands. 

Just use good common sense wire running techniques, gentle bends, grommets, no twisting and plugs pointed down to drain water off, not into connections. The semi clear boot on the side cover connections, large opening down for drainage. 

As I remember you will need 8, 10 and 12 socket and an allen wrench.

If you need help PM me or post, have fun and good luck.
 

[Sambeaux]

 

Great write up - Thanks for the informatiuon

Having not been this way before - is it better to pull the tire to remove the rear section of the fender or can this be done with the bike on the stand?

Thanks again,

Sam

[Pete]

You are welcome.
No need to pull the tire, just the rear part of the rear fender, right side cover and seat. Have fun and good luck.

There are 3 bolts on the rear fender, one on each side rear and 1 centered on the fender.