Wiring Harness question R90/6

[gingerly]

I fried my wiring harness on my '76 R90/6 last riding season. (The green wire melted throughout the whole harness). Anyway, I am now tackling the process of replacing the entire harness, including the killswitch turn signal harness. I might add, I am being very careful with all the documentation, pictures, notes, etc. to keep everything straight. Today, stage one, I disconnected everything in the headlight case. The question is this... two bundles come off the main wiring harness going into the jug. On the old harness, main bundle, there is the large brown wires that go to the circuit board, then to the headlight relay. Then there is a wire out of the same bundle, on the old harness it is a brown with white stripe and plugged into the brown with white stripe section of the circuit board. On the new harness, it is a solid brown wire. My question is: does anyone know if this is the same wire, and if so should it plug in to the b/w section of the circuit board, or should it go to the brown section, or does it not make any difference? All the other wires and coding on the old and new harness are identical. Any help from anyone? Has anyone experienced this? Thanks and I will keep you posted on the progress of this project.

[gingerly]

After making the post I discovered: Looked at the wiring harness, that the wire is for the horn. I guess what I need to know though is if the brown with white stripe is interchangable with the brown on the circuit board. They are not connected as test with ohm meter. Any advice is appreciated. Ed

PS: Will look forward to seeing many on the way to the rally this summer, you should come through Afton and Jackson on the way, it is a great ride, then head over togwatee pass etc. Cheers.

[amiles]

If you don't already have one, Motorrad Elektrik sells placemat sized color laminated wiring diagrams. Seems to me that having one would make your job a bit easier. It would most likely come in handy in the future too.

[sumran]

The number codes are very useful when replacing the harness, provided you have the key. I have one at the house, and it may have a website where the code key can be downloaded.

Let me know if you are interested and I will try to get you the info.

[r60us]

The correct wiring harness for your '76 R90/6 should be part number 61 11 1 358 178 - I have a new one in front of me. This harness is for all /6 models including the R90S commencing with the 1975 model year. If you have an OEM harness, it has a tag on it with the numbers 358 178, unless you have removed it. It has only one bundle of 17 wires that goes into the headlight bucket from underneath. The bundle has one brown/white wire. According to my factory airhead electrical diagram manual, the brown/white wire connects to a brown/white wire from the horn button on the left handlebar switch, via the brown/white section of the headlight board. The brown wire from the left handlebar switch connects to the brown section (code 31, ground) of the headlight board.

Hope this helps.

[gingerly]

R60US and Sumran and the others, thanks for the advice. I do have the correct wiring harness (numbers match 61111358178) I think someone forgot to use the right wire (perhaps it was a friday afternoon and they didn't want to get out a new roll of brown with white stripe). Anyway, the wire in question goes fromthe circuit board, brown with white stripe section and hooks to the horn. I checked continuity on the old harness, (brown with white stripe) and new harness (plain brown) and the wires are one and the same. Also, no continuity between that brown wire and any of the other brown wires in the harness, so I am going to hook it back up the way it was originally. (to brown/stripe area). I appreciate the help though, and Sumran, yes, if you can direct me in the right direction for the wire by number diagram, that would be great. As said, I am being very methodic and each time I disconnect something, I am making sure I know what it is and where it plugged in to. Thanks for all the help guys, I may be requesting more info later. And by the way, I am in Afton WY. on the border of WY/Idaho 60 miles so of Jackson. Anyone headed to the rally this summer this direction is welcome to stop for a cup of coffee, I am in the anonymous book. There are some great rides this way. Cheers and good riding and thanks. Ed Henry