Well, I've been working on cleaning up the wiring for a couple days now. Not really changing anything from the original stock (at least for now) other than replacing a couple messed-up wires. Going through and cleaning all of the connectors takes time, though. In particular the females. The males I can hit with my Dremel and a brass brush. Only a couple of them were corroded (looked like the typical battery acid fume damage) enough to require replacement. Cleaned all of the wires (and sheaths) so that they can be identified when I put it all together. Had to pull both handlebar control boxes apart and clean/lubricate everything. They both had a tone of road dust in them. Looked like the bike had seen a lot of limestone gravel road miles. Taking the connectors apart really is easier with the right tool. I have a
Lisle 14900 terminal tool that works real well combined with a small pair of needle nose. I use isopropyl and 303 to clean the wires. The left control had all three connections to the turn signal control on with cold solder joints that broke off. They were obviously the original Japanese joints, so it surprised me that they were cold. Must have been an apprentice's first day and his supervisor didn't catch it. About all that is left on the wiring (I had already cleaned the engine wiring up while it was apart) is the electrical panel with interfaces, rectifier, regulator, and fuse box. Should get it apart, cleaned up, and back together tomorrow. I've already tested all of the handlebar controls and the key switch, etc. When I took the pins out of a connector, I took pictures and made drawings to make sure I put it back together in order.
My advice for wiring is to have a solid plan before you start, and if you don't have one start with stock and do one system at a time. Unless you really understand motorcycle wiring in which case string that spaghetti! I use Vintage Connections connectors and crimper. Various tools for cleaning like needle files. I'll be getting a .177 (pellet gun) brush next time I go to the store for easier maintenance of the female bullet connectors. I used to have one, but it was left at work when I retired. Just about perfect for the 4mm female bullet sockets. I did soak the majority (the fist full that goes in the headlight bucket) of connectors in vinegar for a couple hours, rinse, and then soak in baking soda solution overnight. That loosened a lot of corrosion. Only two places had corrosion going up into the wire, and I was able to cut back one to good copper and replace all of the other (with doubled #16 wire because it is the main battery ground).
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