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#871496 02/08/22 2:42 pm
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Kev Ev Offline OP
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Hi all,

I will be starting to make up a new wiring harness for my 1966 Lightning very soon and was wondering if anyone had any advice / recommendations on what is best to use for the outer covering. I have seen a few auto electric suppliers online advertising a self adhesive cloth tape that claims to be suitable for motorcycles?

The last time I made up an electrical wiring harness for a bike I used a self amalgamating tape, but I was never really happy with the finished result.

Cheers,

Kev E

BSA on eBay
Kev Ev #871503 02/08/22 3:04 pm
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I do all mine with loom tape, that fabric tape doesn't stick all that great.

Assemble the loom on the frame with all the components in place, keep it tied together with food bag ties (or garden ties. same thing), then when your happy bind it with the tape, remove the ties as you get to them.

For round the head stock, use non shrinking pvc tubing, I use a thickness enough so that all the wires can lay flat, gives them chance to move without getting tought.


Now let’s all have a beer beerchug

68’ A65 Lightning “clubman”
71’ A65 823 Thunderbolt (now rebuilt)
67’ D10 sportsman (undergoing restoration)
68’ D14 trials (undergoing transformation)

Kev Ev #871505 02/08/22 3:08 pm
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Kev Ev Offline OP
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Hi Allan, hope you're well mate.

Is there a particular loom tape that you can recommend?

Cheers,

Kev E

Kev Ev #871507 02/08/22 3:52 pm
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I use spiral wrap to start, makes loom breakouts easier,
but bread threads and garden tape is good..

For final, I 've never been satisfied with anything, including 30+ year old factory stuff.

Agreed, loose covering at the head stock, things are going to move.

Last edited by Chip H; 02/08/22 3:55 pm.
Kev Ev #871510 02/08/22 4:06 pm
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Hi Kevin,

Im good thankyou mate, hope you are too?

These are the guys who I get most of my electrical components from, they do a good varierty of everything and have 99% of the colours you require.

When I originally bought mine they only had the 19mm, its just the right thickness for when you come to a "branch" in the cable.

PVC Harness tape

This is the sleeving.
This for around the headstock, under the mudguard for rear light unit etc


Now let’s all have a beer beerchug

68’ A65 Lightning “clubman”
71’ A65 823 Thunderbolt (now rebuilt)
67’ D10 sportsman (undergoing restoration)
68’ D14 trials (undergoing transformation)

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Kev Ev #871524 02/08/22 6:12 pm
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ALL THINGS CONSIDERED IN MY OPINION PURCHASING A REPRODUCTION Lucas HARNESS IS A BETTER INVESTMENT AND WILL ADD RATHER THAN DETRACT FROM THE VALUE OF YOUR BIKE. $95.00 ON EBAY
https://www.ebay.com/itm/3632484798...msclkid=0e767b931b401185a74e1991aaeb770f


I APOLOGIZE FOR THE USE OF CAPS. I CAN ONLY TYPE WITH MY RIGHT HAND SO USING THE SHIFT KEY IS BEYOND MY CAPABILITES.

The Devil is in the details.

1957 BSA A10 Spitfire Scrambler (numbers matching, very correct, very nice condition)
1965 BSA A65 Lightning Rocket "Clubman" (restored)
1966 BSA A65 Spitfire MK-II (restored)
1967 BSA A65 West Coast Hornet (under restoration)
1975 Norton Commando Roadster (2100 miles)
2001 Kawasaki W650
Kev Ev #871539 02/08/22 10:07 pm
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Problems with standard looms include crap connectors, and all original layout.
By the time you have chopped the loom up to suit electronic ignition, regulator,
maybe a rely or two, and replaced the bullets, you may as well have started from scratch.
As for value, A65's aren't worth much anyway, not as if they were individually hand made,
they were a production bike like most others of the 60'-70's.

2 members like this: Kev Ev, gavin eisler
Kev Ev #871545 02/08/22 11:22 pm
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I use nylon weave sleeve.

https://www.jaycar.com.au/expandabl...j2Z7x9QIVWZJmAh3DCALIEAQYAiABEgIxQfD_BwE

A bit challenging as it will unravel when cut. I cut and then fuse the end with a soldering iron. When loom all sorted, put heat shrink on the ends. You can an pull wires out where you want then to run off from main loom by separating the weave. I found the problem with self-adhesive tape is that it limits flexibility and I got fatigue induced failure of the wires because it concentrated the bending at the head stem to small sharp bends in the wire. I think 'loom tape' is non-adhesive'?

Ray


BSA 1969 A65F
BSA 1966 A65H
Triumph 1968 T120
Kawasaki A1R
& too many projects!
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Kev Ev #871562 02/09/22 2:34 am
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British Wiring sells poly sheath in various diameters. That's what I used when I wired my A65. The only downside, if you can call it one, is that the wires have to be fed through the sheath before the terminals go on, at least at one end. It just requires some planning and careful measuring. It's not original-looking, but it is tidy. And, if you need to make repairs down the road, individual wires can be pulled out and replaced if necessary.


Mark Z

'65(lower)/'66(upper, wheels, front end, controls)/'67(seat, exhaust, fuel tank, headlamp)/'70(frame) A65 Bitsa.
2007 Triumph Bonneville Black
Mark Z #871570 02/09/22 5:19 am
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Originally Posted by Mark Z
British Wiring sells poly sheath in various diameters. That's what I used when I wired my A65. The only downside, if you can call it one, is that the wires have to be fed through the sheath before the terminals go on, at least at one end. It just requires some planning and careful measuring. It's not original-looking, but it is tidy. And, if you need to make repairs down the road, individual wires can be pulled out and replaced if necessary.
+1 for the poly sheath. As mentioned, it does take some planning. I lay out the wires on the bike and cut to length (always leave an extra inch until you put the terminals on.)
I like to use Japanese brass connectors, better strain relief, and a proper crimping tool costs half as much as the Lucar tool. They also take up less space.
I just rewired my Trident and changed to a regulator under the seat, obviating the need for the long hot wire to the Zener under the headlight. At least I could leave the wiring for the Tri Spark as is.
Between the wire, connectors, and sheathing I probably spent less than $50 for the new harness. I'm retired so my time is free.


"Gosh, it's not a 1/4 20, must be metric."

72 T120V cafe project "Mr. Jim"
72 T150V "Wotan"

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Kev Ev Offline OP
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Originally Posted by Spitfire Ken
ALL THINGS CONSIDERED IN MY OPINION PURCHASING A REPRODUCTION LUCAS HARNESS IS A BETTER INVESTMENT AND WILL ADD RATHER THAN DETRACT FROM THE VALUE OF YOUR BIKE.

Hi Ken,

Appreciate your comments but the 'value' of my bike is not really a primary consideration in my rebuild. It's 'value' to me as a hobby and a passion is of far more importance and I like to think that my work on the bike is also serving to make it more reliable and user friendly. I am trying my best to do a good job with the rebuild, but originality is not a factor.

I have a 3 phase alternator, a Podtronics regulator, Boyer Brandsen electronic ignition, fuse box with micro blade fuses and additional relays for taking the load of the switchgear. A standard wiring harness would be of no use to me and that is why I will be making my own up.

Thanks to everyone else for your recommendations.

Cheers,

Kev E

Kev Ev #871581 02/09/22 11:26 am
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Hi kevin, i used twist wrap sleeving for the main loom protection, https://www.vehiclewiringproducts.co.uk/c-58-sleeving/p-54-twistwrap-sleeving.
Very convenient to use. PVC sleeving for the rest. Self amalgamating tape is handy for sealing ends BUT it goes weird if oil gets on it, be careful where you use it.
Spend some time drawing out your options, if you dont use turn signals you can get the main loom spine conductor numbers down to less than 6 cores.
i used two wire gauges, heavy for loads from relays, light for switches operating relays, micro relays make location a lot easier. A2 paper makes drawing out schematics a lot easier.


71 Devimead, John Hill, John Holmes A65 750
56 Norbsa 68 Longstroke A65
Cagiva Raptor 650
MZ TS 250
The poster formerly known as Pod
Kev Ev #871611 02/09/22 6:11 pm
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I usually do my own harnesses. I start with the stock harness off the bike, and maybe a junk one from a swap meet. I like to use the stock wire colors. Makes trouble shooting easier. Where necessary, I buy additional wire with the stock colors from British Wiring. I have one of the nice Lucas connector crimp tools and think it was worth every penny. I buy new connectors as needed from British Wiring. They also sell sleeveing in various diameters (its like shrink fit tubing, but doesn't shrink), that I use for the outside. I make my harness on the bike without connectors. When I am satisfied as to length and placement of the wires, I install the sleeveing and then the connectors. I don't like using tape. The stickiness seems to attract dirt and grime. I am not an electrician by any means, but this method has worked for me on dozens of bikes over the years.

Ed from NJ

Kev Ev #871631 02/09/22 8:23 pm
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Hi Kevin, I have used cloth bicycle handlebar tape a couple of times in the past. It was available at older bicycle shops at one time. Makes for a nice protective cover, but not super sticky, so a drop of Super glue at the end of the tape wrapping would hold it in place.
-Dave


[Linked Image from thebonnevilleshop.com]
Kev Ev #871655 02/10/22 1:08 am
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years ago, i bought a cloth harness tape used by German auto manufacturers. the stuff is top shelf. i used it on my 85 corvette 8 or 9 years ago, and it still looks good today. also use it on my 74 Commando - again, no issues. the brand i used is "tesa" but there are others. go to fleabay, and search "cloth electrical harness tape' - hope this helps.

Last edited by joe czech; 02/10/22 1:10 am.
1 member likes this: Kev Ev
Kev Ev #871668 02/10/22 3:38 am
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I like the black mesh. Stretch to reduce, and bunch up to increase the size. With some thinking ahead, you can have a wire exit through the mesh where needed.

2CB6D022-2395-4FF4-92AE-B43C31B98F1A.jpeg 30A14514-AE68-4A56-B3C7-B36F3D6D300F.jpeg

Down to ‘69 T120R now a Tr6R tribute bike
‘70 TR6C “happy in the hills”
‘67 A65L numbers match, “best effort” from basket *
Gone:
‘66 A65L“in ‘95 getting back in the game”+ empty ‘67 Case&Frame *
‘69 A65L
‘68 A65L “red bike” basket, sold & made whole by BB member
‘68 A65F nice Tribute bike
‘65 A50L bitsa from spare parts, Son’s fun
‘62 A10 Spitfire
‘65 T120R sad case, saved by BB member
'65 XLCH “scratched THAT itch”……
‘93 K1100RS heavy metal (should be gone, still here…)
1 member likes this: Gary E

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