Well, story goes, I went out to work on the Tach and backlighting on the scoot. By the time I realized it, i was sitting in my kitchen with the entire wiring harness in hand. lol So, i'm sitting there labling everything via the book and I found some interesting wires that I am wondering if I really need them or not. So, for those of you that know, please enlighten those of me in my head that don't. jk

The list:
Neutral Switch Sensor Wire
Oil Pressure Switch wire
VOES connection- wtf is that?
California Air Box connection - Would it hurt just to cut it out of the system?

I am guessing the sensor switches are just for the dummy lights and the bike will run fine w/o them wired in, I just want to make sure before I go hacking and cutting.

Just to step it up a bit, what is it worth just to scrap the old trash and make a new one? I think that 400+ for a new one's outragous when I can make my own for less then 100 and learn alot. Also, i am guessing it's all a 24 guage wiring system minus the batter cables and a couple of the ignition cables.

Well ta answer your question?
Gary, The Moderator has a wiring diagram in the DL section that may worth a real good thing for ya ta look at for you?
Its worth a look see?
Jim:tour

Yeah, i got the wiring diagram in the service manual. I was just going for what's necessary or just bish equipment. I'll be lalbling all the crap that was cut and extending / fixing the wiring. I'll take a look though. :)

Yeah, i got the wiring diagram in the service manual. I was just going for what's necessary or just bish equipment. I'll be lalbling all the crap that was cut and extending / fixing the wiring. I'll take a look though. :)

Do your self a big favor and don't mess your original wire harness up? Think about that.
And the best wishes to ya
Jim:tour

Ah, well, that is the problem. The harness was butchered from the previous owner. There isn't much from the tank forward. It's all been cut up and mangled and after figureing out what's cut and isn't cut, there's only 5 wires going to the front of the bike from under the seat out of possibly 20. Just enough to start the bike. No high low, no turn signals, nothing. :( So, while i had it off to fix that stuff, i was going to see what's neccessary for the other parts. If needs be, i can leave it all there wire it back in, no biggie really. :)

Neutral SW: Don't need it, it's just for the green idiot light.
Oil Pres SW: Same thing, just for the idiot lights.
VOES SW: You need this, it's for timing adjustment when you accelerate.
Cali Anything: Unless you're in Cali you shouldn'e have the sensors, thus you don't need the wires.

Most of the wires are 18 gauge. Some in the idiot light area are a bit smaller (20 ga I think?, can't remember).

Do yourself a favor if you make a new harness. Try to use a color code. If you can keep it the same as the factory it will help any shop that might touch your bike later on. But their are a lot of factory colors... thus a lot of wire to buy. Don't just use one color everywhere or you'll hate yourself in the morning.

Gazza

Gary

ok, thanks Gary, Will do. :)

If you decide to eliminate the oil light, You might want to install an oil pressure gauge...

Randum, I'm kind of in the same boat as you. It's not really a headache now, but it will be for next winter's project.

If you decide to eliminate the oil light, You might want to install an oil pressure gauge...

That light has never really existed since I've purchased the bike. He he, i might look into the oil pressure gauge then. Any suggestions?:)

Randum, I'm kind of in the same boat as you. It's not really a headache now, but it will be for next winter's project.

I've been meaning to go through and fix all the stuff that was wrong. It's been annoying the crap out of me and it finally got under my skin. I just can't stand it when something is partially done. Heck, even my rattle can paint job is driving me nuts but the electrical comes first. So, i was out ther fixing / working on the tach and it just got to me and i pulled it out. I've gone though and labled all the wired but the thing is chopped up so bad. I am debating on putting the bathroom renovation on hold and get an entire wiring harness from JP cycles. Handle bars, main harnes, the works. Anyhow, just had to ramble. The wires are making mush of my brain. lol

I am debating on putting the bathroom renovation on hold and get an entire wiring harness from JP cycles.


I can already hear what my wife would say to this dilemma.

I can already hear what my wife would say to this dilemma.

Ha ha ha.


-message to short-

I just went through a front end rewire. Everything from the backbone forward is new. (which is about 80% of all the wiring.) It's not bad at all. Just take your time and as Gary said, use the correct colors. They are available if you look around. I used 18awg automotive wire. It's finer stranding and holds up to vibration better than a standard wire. I spent about 40 bucks on a dozen different colors (25' rolls) and another 20 bucks on various sizes of shrink tubing.
I'm quite pleased with the result. All the hand control wirig is hidden in the bars and the headlight bucket is now empty. The main junction is now located in the tank tunnel. It even resolved an issue I'd had with the turn signals since I've owned the bike.
Each splice is soldered, individually shrink covered, and then the whole bundle is shink covered.

http://moseshorwitz.com/images/Widester/widester6.jpg

http://moseshorwitz.com/images/Widester/100_0751.jpg

Dave where did you buy your wire?

Gazza

BTW Randum, if you need to get new connectors for the wiring job, Batts Racing http://www.battsracing.com/ carries all the various Deutsch connectors and both crimp and solder cup pins for them. These guys used to be a supporting vendor for the forum too! It might be easier to get a large quantity of pins from them than going through your dealer. My dealer usually has about 10 solder pins in stock at any given time, not enough to do a complete rewire.

Gazza

I just tore into mine this past weekend to move all the connectors out of my headlight and speedo and then put them under the seat. Man, that was not for the feint of heart!! I looked and looked at it for about 2 nights after work before cutting a thing. the next night I marked wires. The night after that I marked more wires. I started pulling on Early saturday morning, and I was still soldering connections Sunday night at 6:30. I still have piles of connections to heat shrink. Props to Choppers for the excellent how-to in the "Tips for soldering wires" thread.
For me this was a no beer job that went a whole lot better when I got lots of light and a bit of magnification. I got a bit mixed up dealing with a bunch of grounds that tied together awkwardly, and the white w/ black stripe got a bit confusing...hell, the whole thing was a bit confusing:doh The trick is to allow a lot of time and to be patient as you can. The allow more time;) I wish I had a how to or maybe a list of got-cha's but I didin't allow enough time:p
It'll all be worth it when the UPS guy brings the box with my new headlamp :tour

http://moseshorwitz.com/images/Widester/100_0751.jpg
Wow, that is super nice and clean. I like it.

I just tore into mine this past weekend to move all the connectors out of my headlight and speedo and then put them under the seat. Man, that was not for the feint of heart!! I looked and looked at it for about 2 nights after work before cutting a thing. the next night I marked wires. The night after that I marked more wires. I started pulling on Early saturday morning, and I was still soldering connections Sunday night at 6:30.
You sound just like I was thinking when I pulled mine out. I looked at it and was like, "Ah shit, what did i get myself into now." I just sat down and started having at it and by sunday night was at a stopping point. lol

Props to Choppers for the excellent how-to in the "Tips for soldering wires" thread.
I'll take a look at that to get some good tips. I've worked on my soldering skills w/ stereo wiring and I think it's good enough for something like this.

BTW Randum, if you need to get new connectors for the wiring job, Batts Racing http://www.battsracing.com/ carries all the various Deutsch connectors and both crimp and solder cup pins for them.
Thank you for the link Gary. The internet connection here at work is being a PITA so I'll check it out when i get home.

I went ahead and ordered the harness from JP cycles and it'll be about 7 to 10 days before it ships out. I also ordered the handle bar wiring harness complete with buttons since mine have no wires save for the ignition. They are going to be the 45" version so hopefully i'll have enough to run them under the tank rather then near the headlamp.

Also got the bassani pro-streets w/ heatsheilds enroute. Bu-bye drag pipes! I can't wait. It's really going to suck when the pipes beat the harness here. Oh well. Can't have it all in the same moment or it'de never be fun. Thanks for all the suggestions, i am getting alot of good idea's to keep things clean. :) I'll post when I am done w/ pictures.

Dave where did you buy your wire?

Gazza

I got it at http://www.hosfelt.com/en-us/dept_338.html.

However, looking at the site now, I see only 5 colors showing up. Not sure what's up with that. I'm sure there are other places available but the price was sure nice there.