Triples Team,

As all of you are aware, a lot of our triples are 20+ years old. The wiring harness is a critical component, and should be serviced, whether you're familiar with this item or not. It's not difficult to perform the procedures I am outlining below and only requires a few basic tools and locally obtained materials.

This is a preventative maintenance fix that can eliminate a lot of electrical probems that could occur now or in the near future. It's a bit time consuming, but well worth the effort. Definitely a good cold weather project!

When the wiring harness was originally hand assembled, a lot of circuits that were common to each other were combined with a small crimp type connector within the wiring harness. These connectors can become loose from vibration, and can also corrode causing high resistance connections or no connection at all. It can also lead to high current drain resulting in extreme overheatingof the wiring which results in melted wiring insulation and even fire in the worst cases.

The harness was wrapped with electrical tape to prevent water, moisture, dirt, etc. from deteriorating the wiring and internal crimp connections. You can be sure that the tape is not in the best of condition after the number of years that has passed since it was assembled. Below is a simple way to eliminate future problems:

Materials and tools needed:
1. Rosin core solder, 60/40 preferred.
2. Soldering iron or gun. 40 watts or better preferred.
3. Six inch nylon tie straps.
4. Good brand of 1" or 2" electrical tape.
5. Small side cutters.
6. Small brass brush.
7. Long nose pliers.

Procedure:
1. Start from the rear end of the harness and disconnect all connections and straps holding the harness to the frame. This will also involve removing the seat, gas tank, and whatever else is necessary to remove the harness. Different models have different arrangements.
2. Remove the harness as far as the middle of the frame below the gas tank.
3. Start from the rear and unwrap the tape until you see wiring that has tape over it. Remove this tape from the wiring to expose the crimp connector.
4. Inspect the crimped wiring to see if it is tight and not corroded. If the crimp is loose, tighten it with the long nose pliers.
5. If the crimp is good, solder it to make the connection solid. Don't overheat the connection. Apply solder while heating the connection. Be careful! Excessive heat can melt the insulation! Take your time! Make sure you get solder on all of the exposed wiring.
6. If the crimp is corroded, use the brass brush until the copper wiring and crimp connector are nice and clean. Then proceed with procedure #5.
7. Tape the crimped connection making sure to overlap it 1/2 inch on both sides passed any exposed wiring that has been soldered.
8. Begin taping the harness in an overlapping fashion of 1/2 inch. Tape cables that extent from the harness from the outside towards the harness in the same manner. Overlap these extensions as you proceed along the harness. Use side cutters to cut the tape. Always overlap anywhere you have stopped taping by 1/2 inch when you continue on with taping. When you've reached the middle of the frame below the gas tank, reinstall the harness towards the rear. You will then proceed towards the front of the harness.
9. When finished soldering and taping the harness, use the nylon tie straps at the junctions where extended wiring flows from the main harness to keep these extensions from breaking loose from the main harness when they are stressed.
10. After performing this procedure you will have extended the life of your harness, which will improve electrical performance, safety, and the chance of a breakdown.

Good Luck! I'm always here if anybody has questions. ....Jack....CBMMA #100....