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

[Megadan]

Originally Posted by Thumper

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

I have only built one harness from scratch, and I used the bike to make all of my wiring runs in a rough manner to plan a layout and get my lengths right. I then took it to my work bench and did all of the time consuming parts. The real trick is to make lots of notes for every little thing you think about while doing that initial layout.

Even with doing that, I left a couple of wire ends blank because I wasn't completely sure where I needed to trim due to how the wiring may interfere with other sections once installed.

[Thumper]

Well I got the wiring done and tested. All good, but I need to install a battery. I ordered a battery tray from ebay vendor, and the battery retaining bracket was in 4 photos. I don't need the tray, just the bracket to hold the battery down, but it was included for a low price so I ordered it.

So I received it today, the tray that is, but no bracket.

Gee.

I got a response from the vendor. He said he will "look around". I just asked him to send it. Cripes.

The battery will arrive tomorrow