Oh....dont say that...but I understand. Ouch.
If you really have to rebuild and rewire that is a big project. I just built a new wiring harness.
I'm a newbie so don't take my advice as gospel but here's what I did. My method worked very well. I found the appropriate wiring diagram. Taped big sheets of white paper to my kitchen table. Then I wrote down the names of the components on the paper in the order they appear on the wiring diagram. Then I removed the wiring harness from my bike, labeling each clip and wire as I went. Then I clipped the wiring harness clips (and any male/female connectors) off the harness (with leads that were plenty long!!) and taped them to the appropriate place on the kitchen table.
Then, on my wiring diagram, I labeled each fuse (1,2,3,4) and memorized the circuits according to that numbering system. Then I memorized everything again.
I procured wire, (7 different colors) solder and plenty of heat shrink. I did experiments with many and various connectors but in the end I decided to solder everything because I couldn't find connectors that didn't suck. You might be able to reuse the wire, but I chose to upgrade to 16 gauge, whereas the original wire on my bike was 18 gauge. I'd like to give BIG BIG BIG shout out to Paul at
World Class Wire and Cable in Waukesha WI, ( a wire factory) who provided me with free samples of their 16 gauge automotive wire--saving me a bundle of money.
When I actually built the wiring harness I just took my time, checking and double checking everything. One note: I measured and cut all the Ground (earth) before I started, but I waited until the end to solder it on. This allowed me to build circuit by circuit (maintaining the order provided by the wiring diagram) for as long as possible. This turned out to be a VERY good idea. (LABEL EACH CIRCUIT AS YOU GO)
The trick, I found, is determining the correct length for each wire. I lucked out in this regard. there are only a few wires that were too long (none were too short). But if you know where each component goes on your bike it isn't too difficult to get pretty close. You might find it useful to cut a piece of wood (or another piece of paper) with each component labeled in a linear fashion to guide you when you cut wires. (trace the wiring harness before you cut it up) This is what I would do if I had to do it again.
Beyond that, I found the build to be very intense (took 14 hours). I drank plenty of water and stretched often to keep my mind sharp. Check out my pictures and videos here
http://www.flickr.com/photos/62010758@N08/?saved=1
Once I have it wrapped and completely finished I'll post more pictures. Again, I'm a newbie but this is how I chose to do it.
