Info The joys of loom building - ZXR250 A2

Am currently making a new loom for my 250, not that the one i purchased for it was in bad shape, its just that its 30 year old copper, has been subjected to heat/cold/wet/dry and could just do with a bit of a refresh.

Am almost finished now, this pic was taken the other day, have about 12 more sing-run wires to lay down then its built. Its stock except for removing at source the sidestand and clutch lockout circuits, moving any loins away from low points on the loom to prevent moisture issues, and ive removed the horrible bulky arrangement of wire that was just to the left of the reg-rec, thats now 3 seperate wire runs, so should be a lot more flexible and easier to route.

Need to finish it off, cut it to length, bind and seal it, then crimp the terminals and i have a loom. I have also re-made the front sub-loom for the headlights, i need to do the same for the clocks at some point

 

It's finally laid down. Loosely taped for now, needs a test fit, trim, wrap and connectors then that's one job out of the way.

10hrs down, another 6 to go

 

That's a big job! I did a loom once, but it was for a dirt bike, so it was much easier.

 

I looked at the thread title and thought wonder if he's using pegs board and pegs, you've gone one better...

That's an excellent way to keep yourself occupied during lockdown

 

This is on my to-do list after finding some questionable fixes on mine and burnt out Reg wires
Getting all the colours seems like a pain though

 

Really nice effort , I wish to do something similar, so following with great interest

 

Yes it's just a bit of 18mm thick ply board. I use nails as guides and I include bends now rather than later. I paint the board white so I can draw on it lightly in pencil, then after every loom I use a bit of wood filler to fill in the nail holes, give it a quick paint and it's good to go again.

 

Hmmm what zxr have you turbo'd?

I've considered a small supercharger for my 444 overbore engine, but never really progressed the idea.

 

Will you put the loom in like ducting? Is there a reason why they don't use ducting out the factory for the loom?
You'd think it would protect wiring better than the tape stuff they use...

I know some cars do use ducting (in europe at least),

 

Ducting is useful to protect against rubbing and heat. I used it on the zxr400 loom I made as the loom touches the engine in a few places, but for the 250 it's not needed.

 

Ah that tubing, I thought you ment the rigid corrugated plastic one. I've done looms in the vinyl tubing before, it's quick, but it's difficult to neatly cover the ends of the tubing. It's very good at preventing moisture from getting to the loom so only if I was going to use the bike somewhere very wet would I use it, and I would still have properly bound the loom first as below.

I prefer to use fabric loom tape to bind my looms. Or PVC loom tape. Both of these are non adhesive except to themselfs, so it makes modifications later on a lot easier.

I pre bind my looms with electrical tape every 4", then wrap in loom tape, seal the ends with shrink tube, crimp on the connectors and add in the blocks.

 

I crimp all my connectors and splice joins with non insulated connectors, and use a small amount of solder to improve the connection if necessary.



Hard to take a photo of a black loom, but it's soo much better wrapped than sheathed in vinyl tube.

 

Yeah to be fair i was thinking the corrugated ducting but your handiwork is looking top notch