Mk3 Loom Rebuild

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xstian81
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Mk3 Loom Rebuild

Post by xstian81 » 13 Feb 2017, 09:49

I'm going to have a go at building a new Mk3 loom. I saw jim157 had a wanted thread for a 2nd hand loom, so I asked him to send it over and I would have a go at building a new one. I'm going to be building 2 looms, one for Jim and one for my own Mk3.

This is the loom Jim sent me.
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I would imagine this is how most looms will look like after 20 odd years. I'm not sure how viable purchasing a 2nd hand loom would be?

As you can see from the photos the loom has had a couple of repairs in the past and a couple of connectors have been cut off, but the biggest problem is that the wrapping has been removed. Trying to work out where wire's should exit the main loom accurately is going to be difficult. If anyone has a spare Mk3 loom a few photos would be really handy.

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Re: Mk3 Loom Rebuild

Post by xstian81 » 16 Feb 2017, 16:55

Making a bit of progress with the loom. The plug that is cut off is for the side stand switch. I will have to find out if Jim wants to reinstate this or bypass it permanently.

Someone has added a new Reg/Rec at some point.

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Also the wiring diagram in the FAQ section does not suit a mk3. Although its similar, the mk3 has a few more wires and plugs.

I'm still looking for some photos of a complete loom if anyone can help.

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Re: Mk3 Loom Rebuild

Post by xstian81 » 18 Feb 2017, 07:50

Does anyone know what these terminal are called?

http://www.cycleterminal.com/honda-16-pin-icm.html

Cycle terminals call them ICM which I think is Ignition control module, so referring to the cdi rather than the terminal.

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Re: Mk3 Loom Rebuild

Post by jim157 » 18 Feb 2017, 08:18

Well done for getting stuck into this mate, I'm sorry it's in such a state.

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Re: Mk3 Loom Rebuild

Post by xstian81 » 21 Feb 2017, 15:52

All the parts should be coming today, so hopefully I should be able to get the loom together this week.

Jim, what do you want to do about the side stand switch? Do you want the plug reinstated or permanently bypassed. I think If I keep the plug I can bypass the cutout and keep the side stand light on the dash working, if that suits better?

The connectors are coming up ok in the ultra sonic bath.

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Re: Mk3 Loom Rebuild

Post by xstian81 » 21 Feb 2017, 16:53

This is everything you need to rebuild a loom.

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I made a quick start on the condenser this afternoon, so you can see the sort of finish I'm hoping get. The crimp tool I bought is crap though, so I think I'll send it back and get another before I crimp any more terminals.

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Re: Mk3 Loom Rebuild

Post by jim157 » 21 Feb 2017, 21:19

xstian81 wrote:All the parts should be coming today, so hopefully I should be able to get the loom together this week.

Jim, what do you want to do about the side stand switch? Do you want the plug reinstated or permanently bypassed. I think If I keep the plug I can bypass the cutout and keep the side stand light on the dash working, if that suits better?

The connectors are coming up ok in the ultra sonic bath.

Imagehost image
The cutout bypassed but the light kept would be great mate, many thanks.

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Re: Mk3 Loom Rebuild

Post by xstian81 » 22 Feb 2017, 12:54

Here are the two loom's and the original at the bottom. I'm just waiting for a new crimp tool then I can crimp the internal earths and then start to get it wrapped.

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Re: Mk3 Loom Rebuild

Post by xstian81 » 26 Feb 2017, 11:28

I've got the loom wrapped, but I'm not that happy with the finish, but its my first one. It will work OK, but it looks a little untidy in places.

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I carried on with it and fitted all the terminal Etc.

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I've got to still do something with the side stand switch. I'll have another go at the 2nd loom this week, so hopefully I'll be able to get a better finish.

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Re: Mk3 Loom Rebuild

Post by jompy » 26 Feb 2017, 21:04

I had to rebuild the front half of my R1 loom and I hate electrics but it worked :o
There's a 20 pin white connector on the early R1's that joins the main &front looms together that is a notorious problem so I bought a connector from Amazon to replace it that turned out to be rubbish , so I went down the the local scrap yard & cut a connector out of an mx5
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Re: Mk3 Loom Rebuild

Post by xstian81 » 02 Mar 2017, 16:35

I've finally got the 2nd loom together. This one went together a little better.

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I've just got the small dash loom to put together. I made a start on this today so I should have it finish over the weekend.

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Re: Mk3 Loom Rebuild

Post by gregorious77 » 02 Mar 2017, 17:20

serious dedication in this thread.

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Re: Mk3 Loom Rebuild

Post by jim157 » 02 Mar 2017, 18:11

Fantastic work Christian!

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Re: Mk3 Loom Rebuild

Post by xstian81 » 03 Mar 2017, 16:07

The loom is just about finished. I'm just waiting for one more plug for the side stand switch to arrive.

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The total cost was £96.56 for each loom. I saved a little money by re-using the plastic terminal holders. It saved about £30 a loom. I think If I was to make another I would buy these new where possible. Although most terminals locked back in fine, there is a couple which don't feel as secure as they could be. This should't affect the working of the loom, I will just have to make double sure the connections are lock together firmly.

If anyone else is thinking of making one, its not too difficult. I spent a lot of time researching what type of terminals are needed, 3 different crimp tools. Most of my supply's came from kojaycat.co.uk, a couple of parts from ebay and the cdi plug terminals came from cycleterminal.com in the USA. It took me about 6 hours to build each loom.

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Re: Mk3 Loom Rebuild

Post by jompy » 07 Mar 2017, 19:40

Brilliant work


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