1980 Le Mans rewire

[Manifold]

Hi ho, just embarked on my new years resolution, namely to rewire Claudia, a 1980 Mock 1 Le Mans. I picked her up 12 years ago but I've been working abroad all that time, so just pulled her out of bed.

I think this is going to be fun, based on what I can see of the stock / butchered harnesses. I might get a GB TOT replacement harness, or might build my own as I enjoy electrical work and would like to improve the basic design of the original loom. and use weatherproof connectors.

Couple of questions to start.

Based on what I can see, and the factory wiring chart:

1: Is the standard wiring hot to the ignition switch, handlebar switches and without any main fuse in advance?

2: I'll add relays for the ignition coils, horn, lights, can you recommended an aftermarket fuse/relay powerbox out there?

3: The bike appears to have a stock rectifier and regulator, coils, and seems to be the Bosch system with energised rotor and stator. It works, but it's old.
Is there a replacement reg/rec on the market, ditto alternator replacement (if required farther down the line) and recommended coil replacements?

4: Ignition has been changed to a Pirahna unit, again this works but what is the preferred system these days?

5: I read years ago that the starter system could be improved, as the wiring is routed through the starter button on the bars and can draw a hefty load? Something about a direct strap to the starter? Any additional relays?

I'll have a few more I'm sure, when i get my head round what I have here

A few photos of the old girl. Nice body, bad circulation




and here's the front end. No multiconnectors at all, appear to be wired and spliced straight to the loom, and oh look, insulated connectors in any colour but stock

 

[john zibell]

With a donation to this site you can get the schematic from downloads that will answer many of your questions. Instructions to do that are here:

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Adding relays would be good. Guzzi in that era and beyond put too much current through the ignition and headlight switches. Adding a main relay that energized with Key ON would solve many issues that develop with the stock wiring. Also relays for the headlight unless you go to LED.

 

[Manifold]

Thanks for the heads up there John.

 

[Fuller56]

After reading this thread about adding a relay in the ignition circuit and having had intermittent kill switch issues with Gus ('84 CA 2) for years I did add the relay. It works a treat! Thank you for the inspiration. Gus starts almost instantly, hot or cold and has a much more stable idle. He did well before but much nicer now. So simple and so easy but so effective. Thanks again.