Rewiring the electrical mess aka I hate getting stranded

EDITED........Changed the diagram some

Hi all, been a while...life gets busy. Anyways I have grown tired of fighting with the constant corrosion and broken wires and connectors on my 28 year old 750. I am going to do the minimum wiring thing. I am not afraid to dive in and just rip all of the wiring out and start from scratch. I have the tools, the time, and you guys. I am going to use this schematic

http://www.currentobservations.us/image ... Series.jpg

My problem is that I am a very visual oriented person and I cannot completely visualize the finished product before I get started. So I did this to the schematic (hope whomever originally created this is not offended)


Could someone please let me know what the errors are in this...wiring colors, names, and part pics. Also I am not sure about the unfinished part around the lighting. Why are there different color wires connecting to each other?

Thanks
David

 

I like!
Thumbs up.
But I can't comment on accuracy.

 

i love the pics attached to each wiring lead. makes it "fisher-price" easy to read, great job.
ps, have no idea if it's right, just really like your concept.

 

I agree that the concept is great.
Critique:
The correct wiring positions of the TCI are paramount to a successful harness. A diagram (not unlike the Haynes schematic) would be a very important detail to include.
I would remove the second line from your starter supply line (from the solenoid) and note the polarity of the solenoid.
To answer your question about different color wires connecting, this occurs here and there, the neutral switch is an example. The switch wiring harness (bundled with the pick-up coils) is Blue. The main harness wire connection is Ligh Blue (Sb). It is my understanding that Yamaha is keen on using off the shelf designs (i.e. parts, look at the history of the Radian/Phaser) to build their bikes. This is why the solenoid from the 80 Max will work on the 83 Seca. The the various subassemblies are made, initially, for one particular model and will match that systems wiring colors. Anything else down stream will either have to match the existing components or you will see a color difference. It makes sense to use an existing, solid design and buy large quantities of that design to get the most economy of scale out of it.
When I have time (this century perhaps) I'd love to help you with your quest. Please PM me if you would like some collaborative help.

 

Thanks for the comments...

Robert I see one of the flaws after you had me look at the TCI. I need to point the lines to the appropriate plug positions.

I also need to change some of the wire colors to more closely match Yamaha's

Back to work

David

 

Before you arrive at a finished product; see if you can get a look at an Electrical Schematic by Olsen Engineering.

Two years ago, I had to open a box and take-out a Wiring Harness for a 1967 Corvette.
Having NEVER wired a Corvette before; I asked for the best advice in a 'Vette Forum.

The consensus was: Get a Laminated Wiring Schematic from Don Olsen Engineering.

You have to see one to believe the detail that eliminated questions about what went where.

 

I photocopied my Haynes schematic and laminated it for my garage copy. Can't muss it up with dirt now!

 

The Olsen Engineering Schematic arrives in a large shipping and storage tube.

The Diagram is 3-Feet X 4-Feet.

Every Wire is Color Coded
Every Electrical Device and Part requiring a Hook-up is Pictured and "Proximity Placed" to show you where to look for it's terminus.

 

Though a good idea, looking at a haynes or any other schematic just gives me crossed eyes and even more confusion. I had not given much thought about details when I started this project. I have an 85 airhead maxim wiring harness that I removed from the frame and plugged all of the electrical parts I also removed back into the harness that I will use as a reference. Working through this will definitely give me an understanding of how my beloved maxim's electrics work though. Thanks, David

 

Making a little progress... have a question though. I know what a diode does but I don't know what role the diodes on my XJ play. I think they are dealing with the safety stuff but aren't they important for the charging system too? I don't find them on any minimum wiring plans around here so it must be okay to do away with them, am I right?

I am also using the haynes schematic as well as the 85 harness for reference As painful as it is I think I am starting to understand some of it.

Anyways, I will post the latest progress for critique later

Thanks,
David

My ride, by the way, when I was waiting for some help getting her home (s[color=red [/color] cell phone pic)

Mind the language please, Thanks! Robert.

 

The thing to do is to make a Multi-Member Project of creating a COLOR CODED Wiring Diagram.

Several Members should pick a Bike and agree on a Platform, ... then, each take an "AREA" and produce a Wiring Diagram that will OVERLAP with Sections which others have created.

The Team uses the same Software to enable their Sub-systems to be given to the Team Leader who will use the Sub-system Drawings to CREATE the FINAL Product.

A Comprehensive Schematic to result, ... Fully Color Coded with Test Figures and Data.

The Finished Product able to be brought to a Commercial Copy Store and Printed-out on a Poster-sized Sheet.

In the future, a 3D Halogram that allows the Technician to ride a Virtual Golf Cart along the Circuits and kill Electrical Gremlins with a Nuclear Powered Light Saber and have Robots rewire and repair bad sections automatically may be available depending on how the People of California Vote on Proposition 19.

 

YES WE CANnabis!

 

Hey Rick, that sounds like an old movie I watched wayyyyyy back. TRON
Reminds of a show called REBOOT too.

 

Thats exactly my thought

We also can add animations that will print out on the on the poster

 

so you are not going to be running warning lights???

 

Some of them. I am going to use the gauges off of the 85 xj700 I dismantled. they have the neutral, high beam, turn signal indicators, and oil light. I wanted to use the whole front end but the steering necks are too different and beyond my abilities to make work.
I just haven't gotten the gauges in the diagram yet. I want to be sure that what I have will work before I add all of the other "extras" to it. I also have a smartblink module I am going to work in
http://www.harrisonspecialties.com/mm5/ ... de=MODULES

and a brake light modulator also.

I am hoping for a little more critique on the viability of what I have worked out so far

Thanks,
David

 

David, I'm using DeltaCAD for my drawings ($40) but TurboCAD can be had for less and it is more like AutoCAD. I'm all for diagraming it all up (in my spare time) but I've no idea on how to post it as a jpg or gif file here for folks to use. There is also a free schematic capture program offered by SunStone Circuits (PCB Express). A bit of a pain to download and install as well as a learning curve but free. I'd go CAD over schematic capture since you can do more with it.

 

First off I want to apologize to everyone for my language in an earlier post . I didn't think that one through. I am a truck driver though... :roll:

Okay... Robert, I was actually thinking about CAD myself. I was an architectural draftsman in a former life and still have Autocad 2000 kicking around somewhere. I know that a jpeg can be created out of a .dwg file. Don't remember off the top of my head exactly how to do it but that shouldn't be too hard. There is also a free program (the name escapes me) that can be used to view .dwg files but not edit them. I agree you can do so much with a CAD program. Layering is one that comes to mind that would be useful in this application.

Anyways I have things to do so I'm out for now
David

 

Hope you keep at it! It would sure help those of us (me ) that are schematically challenged :wink: ...

skillet

 

DWG trueview is the program you can download from Autodesk.

2000? Man they're on 2011 now! That's about 9 releases back and was a bad version at that.

Easiest way to make a JPG from Autocad is to up your screen resolution, print screen and copy paste into paint. For line work though try a PNG better quality and lower image size. It leaves out the blank pixels.

 

Think I'm going to stick to corel. I have forgotten too much to make it worthwhile for me to use AutoCad. Can't even remember how to set up a drawing lol. Too many side effects from a past life I guess.

The setup I am making is for what I plan on doing to my bike. It will not be the absolute minimum for it just to run. I do want signals and indicators and probably a 12v source for gps or cell phone charger.

I still haven't gotten a yea or nay to the workability of the updated diagram I have made. If someone could let me know I can continue on.

Thanks
David