Rewire Monster 620 questions???

[Cati]

Hello Tech Team,

I'm thinking about rewiring my Monster 620 myself to save some cash. Basically I got it from a family member for a great deal but you know the story already. Bad wiring cause issues down the line and I just got it back from the mechanic, burnt wire cause the power to shut down on me in traffic. Now it's fixed, the the mechanic told me I would need to get it rewire soon before something else happen.

I have the Hanes manual and checked out the wire diagram in the back of the book. Looks interesting but now to put me up to the test.

Now, how difficult could this be?
Where do I get replacement wire from?
Should I just let the mechanics do it?

I figure it shouldn't be so hard if I take it 1 wire at a time. Any other post, forums, or tutorials on this subject would be great.

Thanks...

[Slide Panda]

Something else to consider would be to scrounge up another wiring harness. It's not at all impossible to find a complete main harness for a 620 on ebay. I picked up a 'spare' for my 900 for a bit over $100. If you consider the cost of wire, the super seal connectors, time etc your final cost of remaking the stock harness would be a good bit more than $100.  Now, if you want to do something custom, that's a different story.

[Cati]

Just checked out ebay and found this harness set for $59

http://cgi.ebay.com/ebaymotors/03-Du...Q5fAccessories

How would I know if these are bad wires. Also what do you mean going custom. I'm interested in doing something different if I'm working on it.

[suzyj]

If you're making a harness from scratch, there's a lot more than superseal connectors that you'll need to source.  You'll also need the connector for the gauges, connectors for the ECU, and various connectors for different bits on the bike (injectors, etc) that although resembling superseal ones, aren't.

There's a thread on oz monsters where we found sources for superseal connectors and for the gauge connector, but the other odd ones are likely to be hard.

http://ducatimonsterforum.org/index.php?topic=41758.0

Much easier to disassemble an existing harness from a wrecked bike and start with that, I think.

[Drunken Monkey]

Buy the ebay harness. Even if you build a new one, you'll want all the wire colors to be the same as stock to help diagnose/repair stuff in the future.

Plus most of these harnesses (off newer bikes) are fine. Whatever killed the ebay bike (crash, most likely) probably didn't effect the harness.

[Cati]

Yeah, I was thinking about getting one of the harness on eBay for a nice price and up grading the wires. Will getting a stronger wire make a difference would it mess something up giving to much power? I checked out the links above in another forum and it seem serious with all the other gadgets such as superseal connectors and things in that nature. I figure take it one wire at a time. I would like to keep wires same color just better thick quality with carbon fiber wrap cover.

[caperix]

I wouldn't worry to much about upgrading the wiring harness unless you have changed what they power.  Wiring problem tend to be caused by something other than the wire its self.  Do you know what the problem was that caused the bike to shut off?  Mis routed wires can be damaged by heat or rubbing and may have caused you problem more than incorect wires.  Pay attention to were the damaged section is when installing the new harness and you may be able to see what the problem is.  Good luck

[Cati]

Yeah, you're right about no need to upgrade wires. I patched up this wire I seen burnt by the motor it was 5 wires connection next to the seat. I use electric black tape to patch it up and moved it from the engine. This probably was why i was blowing the 15amp lights fuse main 30amp back to back. It haven't happened since but cross your fingers I have to commute again tomorrow.

I seen some good wire by the look of the picture and description on ebay for a nice price and may be ordering them soon.