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While it looks
hard, removing and replacing the wiring harness/switches, etc. is fairly simple.
All of the wires are connected by color code. It's just a matter of carefully
separating the connectors.
Most of the wires connect either under the right side cover or in the headlight housing. As I said in the overview, take plenty of pictures so you can see where the wires connect and how they were routed.
Disconnect all the wire connectors on the right side and in the headlight bucket. As these are unplugged, you can remove the attached items (tail light, handle bar switches, turn signals, etc.). Once all are unplugged, the wiring harness can be taken off the frame. Save the clamps for reinstallation.
Once off the bike, I used a cleaning solution of Formula 409, or similar, and wiped all the wires clean. I also cleaned all the connectors inside and out. I used a small file to lightly rub all the brass tabs in the connectors, and pulled on the wires to check for loose connections. Then, I sprayed contact cleaner into all the connectors.
When the frame is ready, the harness goes on first. There's a white line on the front of the harness that lines up with the front of the frame. Line it up and fasten the harness with the removed fasteners placing them where the manual shows. Then, when ready, route all the connectors to the right frame side, following the pictures you took for assistance. Use the manual to route the front wires into the headlight bucket. When ready, connect the wires and all should work as it did before.
Here's a copy of the wire harness and cable routing side and top view, and in the headlight bucket.
If there's any doubt about wire connections, the manual has a good layout of the color codes and locations. Consult this for technical assistance.
Be sure the connectors are fastened both in the headlight bucket and in the side cover. Push them together till you hear them snap. Then pull on them to double check.
The connectors have a holder in each location. Check that they're in their holders.
When you're installing other components, be sure the wires are clear and that you don't crimp or crush any that may cause a short.
Check the main fuse holder. These are known to cause problems. The main fuse wire from the solenoid tends to rub and wear through the insulation. This will dead short to the frame and strand you. If you have any doubts about it's condition, replace the assembly. It's about $18.00 from Honda. Or you can rig one yourself.
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