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T160 re-wire

Home Forums TR3OC Members Forum T160 re-wire

This topic contains 5 replies, has 4 voices, and was last updated by  Anonymous 6 months, 3 weeks ago.

  • Author
  • #8847
    Pete Esser
    Pete Esser

    Greetings all and help! I’m installing a new fabric wrapped Lucas loom on my T160 and have all the other bits I need, including a high output rotor/stator, Boyer Brandsden number 85 kit, etc. I took loads of photo’s when I stripped the bike two years ago to help me on the rebuild, but have misplaced the memory card.

    I would greatly appreciate it if someone is able, to post a few photo’s of  their own machine of the wiring routing under the seat, the coils, and the headlamp and how one reconnects the wiring going into the original six pin plugs (I could not find any new ones); have other members resorted to bullet connectors or is there a better way to do this? Also, I’m not 100% certain how the heavy wiring connects between the starter motor, solenoid and battery, the new ones I got from LP Williams are slightly different in length to the originals and the connectors look different. What would be the recommended connection point from the positive battery lead to earth? I also have a single phase rectifier (200w) to replace the existing one and I believe this will obviate the need for the zenor diode, so I assume I can just tape off these leads? Do I need to alter the wiring to the ignition switch itself with no ballast resistor fitted? Sorry for all the questions, never attempted a full re-wire before but any help would be very welcome.

  • #8851

    Angus McLeod

    If the rectifier you have is purely a rectifier and not a rectifier/regulator you will still need the zenor to regulate the voltage.

  • #8861
    Pete Esser
    Pete Esser

    It is bothimage

  • #8885

    Mike Klose

    Hi Pete.. I can help with some detail about the reg/rec installation..

    (Unfortunately, the other bits of info you wanted are not applicable to my bike)


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  • #8887
    Pete Esser
    Pete Esser

    Thanks Mike, the schematic is helpful. I think I’ve worked out the starter motor wiring now, but not sure on correct routing for heavy lead to battery, it just doesn’t look right tucked under the motor body; I suppose my main concern is plastic sheathing coming into direct contact with hot engine parts.

  • #8896


    I am also at the stage of installing the wiring loom and like Pete would appreciate photos or explanations of the routing of the loom.

    My excuse for not knowing is that I bought the project already stripped

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