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Post by AtariGuy on Mar 2, 2020 13:54:21 GMT -5
So i need advice. I'm gonna start my big chop custom project, and i have wiring diagrams available for a 2 stroke mina configured street scooter, but i need to figure out how to convert a wiring diagram into a full new harness with lighting and turn signals. I do need it to be neat and compact, but it just seems like most wiring harnesses are a bunch of spaghetti as it were. Can anyone direct me to videos or other advice on a diy harness?
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Post by AtariGuy on Mar 2, 2020 14:02:21 GMT -5
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Post by jloi on Mar 2, 2020 17:12:24 GMT -5
sorry to be so dense , but is this for a scooter or motorcycle?
I'm doing my 150 scooter now . if it helps ; pretty far along . I have new bar switches/controls, a new Koso gauge , puttin in a breaker and a 12v charger ; and a 7" motorcycle headlight with H4 led . basically ended up just figuring it out as I go. didn't have an exact diagram . made my own . not perfect. made it huge out of poster board. there are corrections on it - things lined out etc. . tried to keep it as neat as possible . I'm changing out all the molex plugs up front except for Ign and Reg/Rect - for bullet connectors - hoping there'll be less clusterf^$^*(* - in the front ; with the new components there is a lot of wire . 
let me know if you want to see my "diagram" . It was suggested to me by Frankenmech to make a "ladder diagram" . I mostly succeeded but not 100%.
good luck .
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Post by AtariGuy on Mar 8, 2020 5:30:45 GMT -5
sorry to be so dense , but is this for a scooter or motorcycle? Nope, its for a scooter, but principle is roughly the same. Diagrams arent the problem somuch as the actual bundling and splicing and whatnots. I'm looking for the advice about wiring assembly that peole who've done wirings before can pass along. I could use all the help i can get |
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Post by 90GTVert on Mar 8, 2020 7:41:02 GMT -5
Here's where I was doing the last harness from scratch on T2. I made up my own diagram before I started so I had exactly what I was doing on paper to guide me as needed. 49ccscoot.proboards.com/post/323880/threadI also converted as many connections as possible to sealed connections. I used weatherpack. Those are nice because you can go from very small to 10ga wire in the same connectors. The negative is that they are large and quality connectors get expensive. If I did it all over again, I'd consider using metri-pack connectors that can be much more compact, but are still quality sealed connectors. Get good wire and plan out your colors. That's another reason to make your own diagram if you can. Here's where I bought my wire. I bought some on their site and some on their eBay because certain things were better deals on one or the other. 4rcustomswire.com/Don't forget to plan how you want to wrap your wires. I used heat shrink as much as I could and bought multiple sizes. The tricky part there is usually figuring out when you need to put the heat shrink over the wires when you're building. Just kinda have to step back and look it over as you go. Take your time. A good wiring harness is going to take time to build. Period. Do not make this a rush job. If you get tired of it, take a break. Take plenty of time to check your diagram, look at component placements, look the scoot over, and think about your next steps as you go along. Also, get the right tools. If you use connectors that will require something beyond standard crimping, get the right crimper. Trust me. I have crimped things with regular crimpers, but when you are doing a whole harness it pays to have the proper tool that will do it much more quickly and easily. Also, don't get into this with some old wire strippers that barely work. New wire strippers that make quick clean cuts are not that expensive and save you time and headaches. What I did was to start at the front of the scoot and work my way to the rear. The front is going to be the tough spot on most because so much stuff is up there. Building as you work your way down the frame makes it easier for me to plot out where things are headed so I know where to cut wires or where to get wires to leave the main bundle and so on. I wouldn't want to try to build one strictly on a bench. I'm sure you can with measurements though. Also, leave a little slack. Not a lot so everything is sloppy, but make sure there's enough wire that nothing is taut when installed. |
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Post by AtariGuy on Mar 11, 2020 12:31:45 GMT -5
That's the info i'm looking for! All the tips and tricks that help make assembling a harness that works a breeze =D Thanks good sir!
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Post by jloi on Sept 28, 2020 11:57:19 GMT -5
Hey man , hows it goin . I'm wondering how your new harness came out for you ? pics please ?
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