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Post by skeletonscoot on Mar 13, 2019 18:54:24 GMT -5
Hello all!
I have a 2004 Tank 50 classic that I have been rebuilding. I was wondering if anyone has done a simple wiring harness for this or if it is just something that doesn't get done. I have had many problems with this harness and I just want to simplify it down to bare basics. if anyone could help that would be fantastic. thank you and have a good day
Skeleton scoot
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Post by oldgeek on Mar 13, 2019 19:42:10 GMT -5
 A schematic for your particular scoot will almost be a necessity. Here is a manual link for a Tank, but it is a different model than yours. www.49ccscoot.com/manuals/Tank_GY650-150_Service_Manual.pdfIn this particular manual I did not see a full schematic, but there were wiring diagrams in each section, for instance page 169 shows the E-start circuit. Unfortunately there are no universal wiring harness that I know of, you will have to build your own. It can be tedious, but it can be done.
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Post by oakleyscoot on Mar 13, 2019 20:11:27 GMT -5
I just want to simplify it down to bare basics. Skeleton scoot Guess you need to define bare basics....
Simplest is simply a kill switch, just kick start to go, no turns, no lights, no electric start.
Now, if you want a head light, horn, tail light, stop light, turn signals, electric start and a key switch, you already have your bare bones harness.
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Post by milly on Mar 17, 2019 5:07:55 GMT -5
I use to do my own fairly easily when all the electrics were dc and no indicators on my old bsa and triumph back in the day.
This is something I must research to see if I can simplify mine. Haynes manuals do one on motorcycle electronics might be useful, got one myself somewhere best look it out.
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Post by ThaiGyro on Mar 17, 2019 5:28:38 GMT -5
I applaud you for your desire. It can be frustrating or easy. Partly your knowledge and experience, party what you want it to do.
You cannot learn it here, really, but you can gain some insight. Many here have done it!
What I would offer:
*Understand wire gauge spec (8, 10 12...)
*Study the color codes for YOUR scoot
*Write them down, 1 each per function
*Learn how to properly splice/join wires and connectors...REALLY (Crimp connectors are shite!) We call it fray, join, twist, solder. There are good, simple videos. Don't cheap out!
*Study the existing harness...don't just toss it.
That is basic...specific needs?
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Post by 90GTVert on Mar 17, 2019 6:48:34 GMT -5
I have built a few from scratch for my scoots. None of mine were bare bones. As said, that means different things to different people. I made a wiring diagram on the computer (paper is fine) before I ever started so I had a plan. That helped me buy wires, connectors, etc... Might be a good idea to study the old harness and make a wiring diagram of it. If everything works, the idea is right. You may even be able to just modify it. It is a very time consuming process to do a from scratch harness right. I'd advise using good quality wire and connectors. With my last one, I swapped from the Chinese connectors to weatherpack connectors that are sealed. If I did it over, I'd prob use metripack or something smaller that's sealed. Price everything out before you jump in. I put a small fortune into quality wire, connectors, fuse block, etc... for mine. Also think about if you'd want to do a full wave conversion and DC lighting. If interested, that's the time to do it IMO. My diagram below is from my scoot with a full wave conversion and DC lights. Was 1/2 wave with AC lighting before. There are some stock diagrams HERE. I did some system diagrams for my 2Ts HERE, but some of it is relevant to 4Ts.       |
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Post by milly on Mar 21, 2019 2:10:02 GMT -5
Nice one Brent , I shall email that wiring diagram to myself and print some copies off after work Saturday
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Post by lilpinny on Mar 21, 2019 4:50:46 GMT -5
I know with ruckus GY6 harnesses they are $200 and sheer economics says $200 is really cheap for a harness. It doesn’t make sense (cents) to build your own anymore.
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Post by snaker on Mar 21, 2019 20:58:58 GMT -5
I would ask you if your electrical problems are at some mid wire points or at the connections?
I have worked with Avionics, CNC machines and various other machines, some that I built.
I rarely changed out whole wires, only if a bad wire was short enough that replacing was easier than repairing or if the circuit was such that a repair wasn't recommended or allowed.
Now if your changing circuits around like switching AC headlites to DC off the switched DC, then you should consider replacing that circuit wire with a larger (lower gauge).
I know the quality of the Chinese machines is poor, but on mine I would say the wire quality is adequate for what it does. All of the problems or potential problems have been at the connections. Sure you may have a pinched, scuffed or melted wire but that can happen with good quality wires too.
I would suggest you concentrate on the connector pins, maybe replace the whole connector and pins.
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Post by skeletonscoot on Mar 23, 2019 2:05:19 GMT -5
thanks for the input! I just want to learn a thing or two and get rid of this pesky security system that came with the scoot that I never had the key fob for since I got it back in 2013
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Post by skeletonscoot on Mar 23, 2019 2:05:38 GMT -5
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Post by 90GTVert on Mar 24, 2019 7:56:01 GMT -5
If that's all you want to do, I wouldn't build a new harness. Simple method is just to unplug the alarm and see if the scoot still functions normally. Sometimes they won't shut off with the key if you just unplug it and you have to put a jumper between two of the wires in the alarm connection. 49ccscoot.proboards.com/thread/386 |
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Post by skeletonscoot on Mar 24, 2019 11:32:57 GMT -5
So I ended up following all the wires and figured out where they go and what they do. I figured out how to delete the alarm since it wouldn’t run with it simply unplugged. I also inspected the rest of the harness and found a bunch of issues that I am now fixing. I did a bit of research and figured out how to relocate the ignition key, regulator, horn,and got rid of some plugs and wires no longer used like the fuel guage, two of the side blinkers.
I can’t thank you guys enough for all the input I’ve learned a bunch so far and will soon find out if what I did worked!!😃
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Post by ThaiGyro on Mar 27, 2019 21:36:57 GMT -5
I know with ruckus GY6 harnesses they are $200 and sheer economics says $200 is really cheap for a harness. It doesn’t make sense (cents) to build your own anymore.
Maybe that is true in the States or the UK. Not here. I have never spent near that much for any scoot or motorcycle. I think the last complete one I did was a total of $40 to 50 for my TRX 850. I used sealed connectors similar to Brent's pics above. They come with a tube of dielectric grease. A nice option if you get stuck in flooded streets as we often do.
For a GY6...Lazada Thailand shows around 350 THB for a simple harness. ($11) If you are paying $200 for the same thing...shame on the sellers. The quality? Ehhh...
Here is a link to Ali Express, with a whole range of options for your wiring. Not the speedy delivery I am used to, but OK. Prices from $20 to $65. Twenty being basic, $65 with rectifier, alternator and switches. |
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