Guzzi right of passage / Wiring harness

[Turin]

Time for Ye old Gregory Bender Wiring Harness!

The only thing wasn't restored / replaced on my old 850T was the old wiring harness. The old one went right back in after powder coating the frame. The shortcuts you make when short on funds / time. Molex conectors were coming apart, tape etc. Not nice.

So far so good.... Greg makes it easy, and I still may F' it up! 

[Perazzimx14]

I replaced the wiring harness on a T3 after powder coating the frame. What I found was a couple things

1. While it was pretty straight forward I wished i'd have taken a lot more pictures and some video's of the the old harness prior to removal to reference when reinstalling.
2. Triple check wire colors when referencing pictures and comparing to the new winrg. More than once what looked a grey wire in the picture was a white wire new harness. 40 years of dirt, dust have a way of making things look different. Orange, red and brown wires can all get confused.

Anyway its a great feeling once completed and everything works as it should 

[Turin]

I know what you mean about the wires. what isn't filthy is discolored.

I've dreaded doing this, but so far it's not too bad. I'm removing and replacing little by little.
I started with the headlight and only did the headlight. Put the battery back in and it turned over, and the lights worked. Did the same with the ignition switch.
Removed the battery and did the alternator next. low hanging fruit.

Next is the main harness. I prewired the new fuse box matching the connectors on the old. Right now there are two harnesses partially attached. the new fuse box is in place and wired, with the rear lights and turn signal wires in place.

This would suck if it wasn't for Greg Benders harness, and/or if I was starting on a bike with badly butchered wiring.

[n3303j]

I installed a Bender harness on my '76 T3 this spring. A marvelous bit of kit. He was a pleasure to work with. All worked as advertised.

There was an issue from the factory where the connecting plug between the harness and headlight shell would be wiggled free by repeated steering movements. Guzzi attempted a fix that didn't work. I ran a very skinny zip tie between the wires and around the back of each plug with the zip end hidden in the headlight shell. The tie was hidden by the rubber boot on the outside. Those connectors aren't t going to come apart.

I also wasn't thrilled about how the main harness flexed around the head tube in cold weather. I slit off the plastic jacket and replaced that section with the braided automotive loom jacket. It all moves smoothly  now.

It will be the first time all your lamps see full voltage since the bike left the factory. About a third of my bulbs failed in the first few hours after the new harness was installed. I installed all new bulbs and everything is working as advertised. I also added a $10 (Amazon) voltmeter to be able to keep a closer watch of the charging system.

[Turin]

there were zip ties holding the molex connectors in place inside the headlight shell, etc.