Deleted account 211025001
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The ‘79 California Rebuild Thread
- Thread starter Nin
- Start date
Thanks chaps - yes he’s on my speed dial now ...
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Well I've just found out how much he charges, so let's think again ....
It's time to confront my fears, and learn how to do this properly. I'm guessing this not be my last rebuild so I'll take the opportunity to learn something useful along the way. Don't think I'll be getting this finished in time for DGR at the end of Sept though!
I've been in touch with Rupe's Rewiring, got some guidance and downloaded his "how to" guide.. Wet towel wrapped around the head to avoid overheating, let's get learning!
It's time to confront my fears, and learn how to do this properly. I'm guessing this not be my last rebuild so I'll take the opportunity to learn something useful along the way. Don't think I'll be getting this finished in time for DGR at the end of Sept though!
I've been in touch with Rupe's Rewiring, got some guidance and downloaded his "how to" guide.. Wet towel wrapped around the head to avoid overheating, let's get learning!
Have you tried thrashing it to within an inch of it's life, and threatening it with a can of petrol and a zippo?
That usually works wonders
Making a new loom isn't that hard, but it can be a ball ache
We used to draw the loom on a big board, with all the required coloured cables on a bar at one end.
Mark the branches and then start from one end and run the lengths - normally plugs are within 15-20mm for tolerances & bends etc
Terminate plugs etc as you run each run, other wise there is a risk you can get the wrong plug on the wrong run
The days of fully amalaga wrapping harness's are long gone and its more of an open wrap now. Just fully wrapping at branches and risk areas
That usually works wonders
Making a new loom isn't that hard, but it can be a ball ache
We used to draw the loom on a big board, with all the required coloured cables on a bar at one end.
Mark the branches and then start from one end and run the lengths - normally plugs are within 15-20mm for tolerances & bends etc
Terminate plugs etc as you run each run, other wise there is a risk you can get the wrong plug on the wrong run
The days of fully amalaga wrapping harness's are long gone and its more of an open wrap now. Just fully wrapping at branches and risk areas
Ha ! Yes I had considered that, but first rule of parenting is to be willing to follow the threat through. I do t think I could.
I’ve got a new core loom coming, will use that as the basis for the rest of it, good advice on the layout board idea, I’ll give that a go.
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I’ve got a new core loom coming, will use that as the basis for the rest of it, good advice on the layout board idea, I’ll give that a go.
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Not wishing to sound smug but I find troubleshooting pretty straightforward if a bit time consuming. Putting the whole loom on a board is one way. Connect the battery and just trace the wires and connectors using a test lamp. This won’t test the individual components like electronic ignition or voltage regulator but you can connect all the lights, relays and the horn - which is why I prefer to leave the loom on the bike (possibly worth linking all the earth points on the frame). Don’t get bogged down with differences between wiring diagrams or wire colours but don’t assume new switches have the right pinout or that Guzzi diagrams are any use at all, for example. At least you know your connectors are good.
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On average,it takes me two days to build a bespoke loom,Well I've just found out how much he charges, so let's think again ....
It's time to confront my fears, and learn how to do this properly. I'm guessing this not be my last rebuild so I'll take the opportunity to learn something useful along the way. Don't think I'll be getting this finished in time for DGR at the end of Sept though!
I've been in touch with Rupe's Rewiring, got some guidance and downloaded his "how to" guide.. Wet towel wrapped around the head to avoid overheating, let's get learning!
Plus @£100 in consumables.(not including switches relays pdm60 etc etc)
That’s a stripped back basic no frills loom.
That would add up to well over £1k
It’s not that hard, I rebuilt my cafe racer completely from scratch,
The trick is to break it down into single circuits, and understand how they work, for instance,
Indicators,
Fuse box to flasher unit, flasher unit to handle bar switch indicator common, left to left indicators, right to right indicators, with a take off to the idiot lights,
You find out what does what with the switchgear using a multimeter
Iirc the starter is actually switched Earth, so the starter relay is wired and the earth to it goes to the switch, through the switch and to earth,
You go through the bike circuit by circuit, and suddenly you have a new loom,
Get a wiring diagram and do it circuit by circuit.
The trick is to break it down into single circuits, and understand how they work, for instance,
Indicators,
Fuse box to flasher unit, flasher unit to handle bar switch indicator common, left to left indicators, right to right indicators, with a take off to the idiot lights,
You find out what does what with the switchgear using a multimeter
Iirc the starter is actually switched Earth, so the starter relay is wired and the earth to it goes to the switch, through the switch and to earth,
You go through the bike circuit by circuit, and suddenly you have a new loom,
Get a wiring diagram and do it circuit by circuit.
Cheers Ian
You’re bang on. Despite all my moanjng I have done quite a few 12v installations in small fishing boats years ago (now there’s a hostile environment for electrics). Trouble is I’ve forgotten most of what I learned.
This is a great opportunity to re-learn some useful skills, so well take it slowly and systematically.
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You’re bang on. Despite all my moanjng I have done quite a few 12v installations in small fishing boats years ago (now there’s a hostile environment for electrics). Trouble is I’ve forgotten most of what I learned.
This is a great opportunity to re-learn some useful skills, so well take it slowly and systematically.
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New main loom arrived today and I can immediately see where the original loom is different, and looks like it has been altered.
Hopefully I’ll get some time at the weekend to work it through.
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Hopefully I’ll get some time at the weekend to work it through.
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Deleted account 211025001
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Thank you Nin for making me get up off my lazy arse 
Sooooooo...........
Light Switch ~
Old switch has 13 wires at the switch (2 x black/blue) & 13 wires out to the connector block (2 x black/blue go into one pin).
New switch has 13 wires at the switch (2 x balck/blue) & 12 wires out to the connector block (1 x black/blue goes into one pin).
The above threw me initially but I can only assume the 2 x black/blue wires are spliced together somewhere in the short switch loom (I wasn't gonna unwrap it to find out).
My issue with things not doing what they should was down to the green & green/black wires being swapped in the new switch V the old one. Once I swapped those over in the connector block all was good.
Diagrams below show old V new switch wiring and where I've written 'top' & 'bottom' that refers to how the switches present themselves to you when held open like this
<a href="https://andressotoscastello.smugmug.com/UkGSer/n-5CFLKf/i-W3HZS7B/A"><img src="https://photos.smugmug.com/photos/i-W3HZS7B/0/b952e485/XL/i-W3HZS7B-XL.jpg" alt=""></a>
Here's the layout of wires; old V new. You can see the green & green/black swapped over
<a href="https://andressotoscastello.smugmug.com/UkGSer/n-5CFLKf/i-dvJ3vhL/A"><img src="https://photos.smugmug.com/photos/i-dvJ3vhL/0/f48218f8/XL/i-dvJ3vhL-XL.jpg" alt=""></a>
When looked at head on like this
<a href="https://andressotoscastello.smugmug.com/UkGSer/n-5CFLKf/i-ScL38zH/A"><img src="https://photos.smugmug.com/photos/i-ScL38zH/0/a9083247/XL/i-ScL38zH-XL.jpg" alt=""></a>
The 'correct' wiring should be as follows
<a href="https://andressotoscastello.smugmug.com/UkGSer/n-5CFLKf/i-xrSGTF5/A"><img src="https://photos.smugmug.com/photos/i-xrSGTF5/0/2e451e13/XL/i-xrSGTF5-XL.jpg" alt=""></a>
Of course, that all assumes my main loom and yours are the same
HTH
Andres
Sooooooo...........
Light Switch ~
Old switch has 13 wires at the switch (2 x black/blue) & 13 wires out to the connector block (2 x black/blue go into one pin).
New switch has 13 wires at the switch (2 x balck/blue) & 12 wires out to the connector block (1 x black/blue goes into one pin).
The above threw me initially but I can only assume the 2 x black/blue wires are spliced together somewhere in the short switch loom (I wasn't gonna unwrap it to find out).
My issue with things not doing what they should was down to the green & green/black wires being swapped in the new switch V the old one. Once I swapped those over in the connector block all was good.
Diagrams below show old V new switch wiring and where I've written 'top' & 'bottom' that refers to how the switches present themselves to you when held open like this
<a href="https://andressotoscastello.smugmug.com/UkGSer/n-5CFLKf/i-W3HZS7B/A"><img src="https://photos.smugmug.com/photos/i-W3HZS7B/0/b952e485/XL/i-W3HZS7B-XL.jpg" alt=""></a>
Here's the layout of wires; old V new. You can see the green & green/black swapped over
<a href="https://andressotoscastello.smugmug.com/UkGSer/n-5CFLKf/i-dvJ3vhL/A"><img src="https://photos.smugmug.com/photos/i-dvJ3vhL/0/f48218f8/XL/i-dvJ3vhL-XL.jpg" alt=""></a>
When looked at head on like this
<a href="https://andressotoscastello.smugmug.com/UkGSer/n-5CFLKf/i-ScL38zH/A"><img src="https://photos.smugmug.com/photos/i-ScL38zH/0/a9083247/XL/i-ScL38zH-XL.jpg" alt=""></a>
The 'correct' wiring should be as follows
<a href="https://andressotoscastello.smugmug.com/UkGSer/n-5CFLKf/i-xrSGTF5/A"><img src="https://photos.smugmug.com/photos/i-xrSGTF5/0/2e451e13/XL/i-xrSGTF5-XL.jpg" alt=""></a>
Of course, that all assumes my main loom and yours are the same
HTH
Andres
I have powers beyond my ken. Thanks Andres, I’ll take a look at mine later ...
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A quick update - sorry no time for lots of pics.
New loom arrived and a comparison with the old one showed there had been quite a lot of off piste wiring going on. So setting up the switch gear blocks as per Andres’ example above was always going to give problems.
Although there is also an error in the wiring up of the brand new switch (black and green wired to the terminal that should have had green, and vice versa). And an error on the new loom (blue wire for rectifier 61 positioned for the front brake light switch).
Anyway everything checks out now and works on the bench, so hopefully I’ll get some time over the next week or so to get it fitted.
Once I’m sure it’s all working I’ll upgrade a few of the circuits to run off dedicated fused circuits from the battery via separate circuits triggered by relays.
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New loom arrived and a comparison with the old one showed there had been quite a lot of off piste wiring going on. So setting up the switch gear blocks as per Andres’ example above was always going to give problems.
Although there is also an error in the wiring up of the brand new switch (black and green wired to the terminal that should have had green, and vice versa). And an error on the new loom (blue wire for rectifier 61 positioned for the front brake light switch).
Anyway everything checks out now and works on the bench, so hopefully I’ll get some time over the next week or so to get it fitted.
Once I’m sure it’s all working I’ll upgrade a few of the circuits to run off dedicated fused circuits from the battery via separate circuits triggered by relays.
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Attachments
BTW Andres, Liberace called. He’d like his bracelet back.
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All done. Unfortunately we discover that the starter motor soleniod is as sticky as a sticky thing. And in prepping the tank to fit, we discover that the paint shop has had a bit of a brain fart.
Pinstripes are different widths left and right on tank and side panels, and lower narrow pinstripe is missing. Back they go.
Pinstripes are different widths left and right on tank and side panels, and lower narrow pinstripe is missing. Back they go.
Deleted account 211025001
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Sticky solenoid ~ just got myself a recon starter/solenoid from Gutsibits the other week...........I was going to try and fix it and then thought better. Very pleased with it and the bike now starts better than it ever has done (it was never a 'bad' starter) 
Bad luck on the paint, what a pain!
Andres
PS .....and no, Liberace can't have ANY of his jewellery back!
Bad luck on the paint, what a pain!
Andres
PS .....and no, Liberace can't have ANY of his jewellery back!
Morning fellas
Not made much progress on this as life intervened. So it’s not going to be ready for DGR sadly.
Since the last post I’m half way through re wiring the thing, so once done it’ll have all primary loads running through fused supplies via switched relays.
Whoever designed the original wiring layout had a bit too much Grappa at lunchtime!
À bientôt
Not made much progress on this as life intervened. So it’s not going to be ready for DGR sadly.
Since the last post I’m half way through re wiring the thing, so once done it’ll have all primary loads running through fused supplies via switched relays.
Whoever designed the original wiring layout had a bit too much Grappa at lunchtime!
À bientôt
Quite a lot going on at Nin towers in the last few months but I’ve managed to make a start again on this which has been a pleasant change.
All the wiring is sorted now - it has a full new bespoke loom with all loads running off fused spurs and switched relays.
Cookie will be pleased to hear all connectors are crimped not soldered.
Tanks and panels are back from their second trip to the spray shop after spray dude had a brain fart and drew the pinstripes on with crayons in the dark.
I’m going with decals (sorry Chris, rest easy fella). And had a reasonable go at some today.
More to come ...
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All the wiring is sorted now - it has a full new bespoke loom with all loads running off fused spurs and switched relays.
Cookie will be pleased to hear all connectors are crimped not soldered.
Tanks and panels are back from their second trip to the spray shop after spray dude had a brain fart and drew the pinstripes on with crayons in the dark.
I’m going with decals (sorry Chris, rest easy fella). And had a reasonable go at some today.
More to come ...
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