I was lucky enough to have a complete (but degraded) harness on my 16H. I used vinyl cable abraded with 'Scotchbrite' and it looks very similar to rubber. As modern insulation is thinner than the old rubber, I had no concerns about the rating of the cable and wanted to replicate the external diameters of the original installation.

There were two main sizes of cable in the WD16H loom. This is a copy and paste of information that I passed on some time ago.

"Diameters are external including insulation. They give an idea though of where the heavy stuff was used. Diameters are approximate and may be slightly less (0.2mm or so).

The main feature of the loom is the length of rubber tube (bicycle inner tube !) running from inside the headlamp along the frame top tube.

Mine is 950mm long and 15mm diameter. It contains three cables - Battery to Ammeter, switch to tail light and switch to 'A'.

These are all 5mm insulation OD

Ammeter to horn and horn to horn push are also 5mm OD.

Main switch to pilot bulb - 5mm

Dynamo to 'F' and 'D' - 4mm

'E' to earth - 4mm

All the rest seem to be 4mm except that I found a short length with an eyelet on one end (internal headlamp earth maybe ? ) - 3mm OD.

The wiring from the dipswitch was a 3-core multicore with an OD of 9mm. I used standard black round modern 3-core cable. Scuffed with Scotchbrite, it looks fine".

I must have a note somewhere of what I actually used.

Now you tell me!!! hahaha, well no harm doen, found out that the wire I use, copes with it all, and there's no real alternative.

Thanks,

Lex

email (option): welbike@welbiXX.net (think about it!!)

Dear all

Thanks for the additional information greatly appreciated.

Lex

What are the special wiring connectors for and where are they located on the bike, Mine is a 1943 BSA WM20.

Regards

Stuart

email (option): deepsea@vol.net

Although they don't appear to be shown in the wiring diagram, there is always a connector at the tail lamp, especially handy for the drop off or hinge up mudguard tail piece.... On an M20 I think there is also one on the main battery lead above the battery.

The connector is covered by a slide over piece of rubber tube. Here's an original on my James ML. Ron

email (option): ronpier@talk21.com

Hi Lex

Could you put my name on a roll of your wire please. Cheers Barry

email (option): deadhorsesdontgetbackup@hotmail.co.uk

Dear Lex

I have manages to source the wire locally in Hong Kong so I will buy this end instead, it will save on the postage as well, they actually have 108 rolls in stock if you run out in the UK.

Regards

Stuart

email (option): deepsea@vol.net

Hi Lex

Have also found some in New Zealand and this will save quite a bit on postage.
But would be interested in 4 of the special connectors

Kind Regards Barry

email (option): deadhorsesdontgetbackup@hotmail.co.uk

Hey Lex,

Do you have any of those "special electrical connectors" that you would off load for my 16h???

Cheers,

Ben.

email (option): Benjamincameron75@gmail.com

Ok, I will have a look next week what connectors are left!

No worries,

Lex

email (option): welbike@welbiXX.net (think about it!!)

Thanks Lex.

Ben.

email (option): Benjamincameron75@gmail.com

Ok, got some rolls in!!

Email me please, who wants a roll? welbike@welbike.net

Cheers,

Lex

email (option): welbike@welbiXX.net (think about it!!)

Hey Lex,

Any luck locating some of those special little electrical connectors for my 16h?

Cheers,

Ben.

email (option): Benjamincameron75@gmail.com