KTM 250SX conversion

[Thumper]

Originally Posted by Megadan

Nice work so far. Wiring a bike like that is time consuming and tedious, so I give you some credit. That SPST switch you chose is the exact same switch I used to activate the relay for my spot lights I mounted to my Hawk, and it is a very good switch.

Now that I am getting through this project, I can tell that wiring harnesses are built on benchtops where you can pull wire, the right gauge and color(s) and length, and assemble them with all of the tools, fittings, insulation, heat shrink sleeves, and a soldering gun based on known lengths.

Making one on the bike adds some real challenges! Add to that adapting new mounting places for things like non-OEM relays, horn and flasher and you have a lot of slow work. Yes, time consuming and tedious nails it. Working upside down over the rear tire was no fun, fortunatley not much wiring to do there!

If you do this on the bike, take this advice- Don't actually try to connect things while you are doing it. It stresses your fitting connections. Crimp the fittings and label them. Get it all ready, then when everything is ready, connect and assemble