Rebuilding curvy wiring harness?

My 12 years old SV is in need of fresh wires...

After a long history of eletrical issues, I did a inspection and found lots corrosion, from green to rust, mostly at connection blocks. If not corroded, all the metal surfaces are dulled with a coating...

Most wiring has hardened with hairline cracks + there a few cheap repairs over the years with soldering and tape holding them together...

So where do I start? Any pass project on here I can refer to? What equipment and products will I need for a complete rebuild?

This will end up being my winter project

Cheers!

Lucas

[TamSV]

If it was me I'd get the loom out the bike, stretch it out, unwrap it and decide what needs replaced and what can be saved. Photograph it and replace/replicate a bit at a time.

This site may be useful. It's not the easiest to navigate but there's a fair amount of OEM equivalent connectors and other useful stuff there. I've used them for various bits and pieces on both the SV and RGV. I recently got just the male side of a broken connector that plugged straight into the original Suzuki female.

You'll save yourself a fair few quid if you can save the old connectors. You can get the old terminals out with a small precision screwdriver easily enough and then just get a big bag of new terminals to crimp on. If the wire is sound, you could just clean up the old terminals and stick them back in. I use this inside the connectors and it keeps the corrosion from returning.

If you're replacing actual wires, try and stick to the same colour coding as existing. It'll save the next owner from cursing you. The Kojaycat site has a good range of colours in 1m lengths.

Tools : soldering iron, crimping tool (proper ratchet one for non-insulated terminals - not the cheap crappy ones for insulated terminals), wire cutter/stripper and a wiring diagram.

There is a full curvy loom on ebay for about £12, what if you bought another loom, to make nice, then just swap it in, if something is wrong, you`ll have your original to refer to.

thanks for the info guys.

What wire rating (mm² & amp) & terminals will I need for the main harness (no 1) ?

Thanks!

thanks for the info guys.

What wire rating (mm² & amp) & terminals will I need for the main harness (no 1) ?

Thanks!