Wiring harness

[Martin S]

I have been looking for a wiring harness for my 1965 Lightning; unfortunately without success. Can someone with better knowledge of electricky advise me if I can use one from a later model? My ignition switch and lighting switch are in the headlamp shell.

[DAVE BRADY]

Hi Martin,

Assuming he is still in business, Al Osborne does a harness kit.  It is model specific and comes with all necessary wires, connectors, tape and instructions.
I used one last time I did complete rewire.  He trades as AO Services.

Dave.

[DJC]

If you are still looking for a harness, try C&D Autos. Mark is very knowledgable and very helpful (he has been advising me on my harness options for a '66 Lightning but with a later toggle light switch).

[Martin S]

I eventually got one from Classic Motorcycle Spares in Swindon. It is for a 66 model year, not a 65 which is what mine is, but it fits fine, should be running in the next couple of days.
Nigel at Classic Motorcycle Spares was extremely helpful and talked me through connecting the power box.

One of the things I learnt whilst searching was that in the 60s British motorcycle manufacturers standardised the colours for wiring harnesses, which I find very enlightened for such an entrenched industry. As bikes are all of similar size, give or take an inch or two, does it mean that I could have used a  harness from another  twin cylinder bike?

[wardy]

Back in the day used to repair/supplement my wiring by scavenging stuff off old British cars at scrapyards as they used the same wiring styles and colours, bullets and Lucar connectors etc. Not sure if this is still a runner but thought it worth mentioning

[DAVE BRADY]

Hi,

I can remember doing the same and some nice chrome nuts as well.  I have Jaguar head bolts and rocker nuts in use in various places. I do not think that scavenging in scrapyards is allowed these days.

Re the wiring, the harnesses will be similar but things like coils and rectifiers will be in different locations so the tails for them may not reach or even be in the right place.  Likewise switches varied in location and function.  Even between similar models like early 6v A65, 12v A65 with Zener diode, OIF A65 with the switch in a different place.  However, they could all be modified if needed.

Dave.

[Mike Farmer]

 

I've put a later one on mine but I've ended up with some unnecessary wire tucked away in places.

Mike

[DAVE BRADY]

Hi,

I will probably rewire one of my bikes next winter.  The harness had been on it for some time and due changes and additions it is getting a bit untidy and quite brittle.  Isn't it a pain the way the wires go brittle.  A relatively simple job like fitting a new primary chain gets out of hand when the alternator wires need to be sorted before putting it back on.  As mine is non standard due to no Zener, electronic ignition and indicators I think I will get a kit from Al Osborn.  Everything you need for a bespoke harness with as few joins as possible.

Dave.

[geraldhattrick75]

Not sure if this helps but it might be worth making your own wiring loom.
I've just done one for my 1965 (ish) BSA A65, after drawing the diagram on 'office'.

My A65 has no zener or rectifier stack- i've fitted a Wassal reg/ rect, Boyer Mk4 electronic ignition system and indicators... And, by an amazing fluke the light, horn and ignition all seem to be working.... (who'd have thought eh?)

As I say, just in case it might be useful...
Regards,
Dave

[ChrisG]

I tend to use the original harness and replace wires that have cracked or melted insulation etc. I also replace the bullets that are hanging on strands of wire and look like they are about to give up the ghost. I always by the wire and bits from Vehicle Wiring Products and use fresh sleeving when necessary. They do all the colours you need and the correct gauge wires etc.
I think the reason why all manufacturers used the same colour coded wires was probably down to Lucas who supplied most of the equipment to all of them and they probably led the way on standardisation.

[geraldhattrick75]

Absolutely. No point throwing good wire away.

I used what was useable of the original and bought the rest......