Help needed with rewiring - Kawasaki Vulcan 750 Forum : Kawasaki VN750 Forums
Electrical
Where does this wire go?
Includes Electrical mods, Lights, Stator,
Rectifier, Diagrams, etc

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post #1 of 54 (permalink) Old 01-17-2019, 02:49 PM Thread Starter
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Help needed with rewiring

Hello everyone, so this last couple of weeks i have been busy replacing the stator. Removed the engine and replaced it, then put everything together. Last thing i need to do is a couple of wires that i dont know where to connect them. Ive added a couple of photos and will add more when i come across some more loose wires.all lights work including headlight. So this yellow wire at thethe front of the bike i dont know where to connect. And also noticed a wire with a iron ring on it that isnt connected at the back of the engine. Anyone know where to connect these two?
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post #2 of 54 (permalink) Old 01-17-2019, 04:03 PM
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Yellow wire up front should go to the temp sender, at the thermostat housing under the tank, not the radiator.

What color is the wire at the rear? Larger cable with a ring connector, black/yellow stripe, would be a frame ground, or one of the grounds to the battery.

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__________________________________________________ ____________
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post #3 of 54 (permalink) Old 01-17-2019, 04:30 PM Thread Starter
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The wire at the rear is connected to the battery box, its thick and black. Does that go to the backside of the engine block?

Also when i try to start the engine (there is no cooling fluid and oil in the bike) i hear a fluit like noise coming from the right side of the exchaust which is not conected yet, then sometimes it gives a backblow like when your battery is below 12v
Edit: it comes from the exhaust box which connects the echaust coming from the engine and the muffler. at the engine side of the box (the one who connects with the exhaust to the engine block)

Sorry for my poor explenation. Im still a rooky and dont know many of the english part names.

Does anyone know what im missing? The battery is charged to 12.7V and is 12,2 when the lights are on.

Last edited by Panarock; 01-17-2019 at 04:35 PM.
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post #4 of 54 (permalink) Old 01-17-2019, 05:12 PM
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Originally Posted by Panarock View Post
The wire at the rear is connected to the battery box, its thick and black. Does that go to the backside of the engine block?

Also when i try to start the engine (there is no cooling fluid and oil in the bike) i hear a fluit like noise coming from the right side of the exchaust which is not conected yet, then sometimes it gives a backblow like when your battery is below 12v
Edit: it comes from the exhaust box which connects the echaust coming from the engine and the muffler. at the engine side of the box (the one who connects with the exhaust to the engine block)

Sorry for my poor explenation. Im still a rooky and dont know many of the english part names.

Does anyone know what im missing? The battery is charged to 12.7V and is 12,2 when the lights are on.
How long is the cable off the battery box? If it's short, I'm thinking it should go to the battery negative post. Depends on the size of the ring connector on it, if it matches the battery terminal bolt, put it on the negative post. Cable should be black with a yellow stripe, all grounds are that color.

The sound you're hearing is probably just compression going into the 'goat's belly', sounds like it's trying to fire, so get some oil in it.

12.2v is on the low end for voltage with the key and lights on.

2003-21k mi
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__________________________________________________ ____________
Repair Manual: http://www.mediafire.com/file/mj7z81..._Catalogue.pdf

Owner's Manual: http://www.mediafire.com/file/nscb5f...ers+Manual.pdf
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post #5 of 54 (permalink) Old 01-17-2019, 05:23 PM Thread Starter
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Its this wire, its funny because if this goes on the negative pole it wasnt on when I bought it.

Also I noticed the clutch cable is loose, how do I tighten or connect it properly?
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post #6 of 54 (permalink) Old 01-17-2019, 05:34 PM
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Quote:
Originally Posted by Panarock View Post
Its this wire, its funny because if this goes on the negative pole it wasnt on when I bought it.

Also I noticed the clutch cable is loose, how do I tighten or connect it properly?
The loop connector does look like the right size for the battery, should run behind the frame and up to the neg. terminal.

The clutch arm looks aligned correctly, see if you can take up the slack with the adjuster at the hand lever. If not, there's another cable adjustment about halfway down the left frame downtube.

2003-21k mi
Shaved w/UniPK92+Stock Jets-TPE/MOSFET-Shinko Tires-AGM batt-bags-chrome-LEDs...more
__________________________________________________ ____________
Repair Manual: http://www.mediafire.com/file/mj7z81..._Catalogue.pdf

Owner's Manual: http://www.mediafire.com/file/nscb5f...ers+Manual.pdf

Last edited by Spockster; 01-17-2019 at 06:05 PM. Reason: typo
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post #7 of 54 (permalink) Old 01-17-2019, 05:52 PM
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Quote:
Originally Posted by Spockster View Post
The loop connector does look like the right size for the battery, should run behind the frame and up to the neg. terminal.

The clutch arms looks aligned correctly, see if you can take up the slack with the adjuster at the hand lever. If not, there's another cable adjustment about halfway down the left frame downtube.
also, make sure the shaft the clutch arm mounts on is rotated all the way.. I dont remember which way, but it must be all the way when the lever is attached
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post #8 of 54 (permalink) Old 01-17-2019, 06:04 PM
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also, make sure the shaft the clutch arm mounts on is rotated all the way.. I dont remember which way, but it must be all the way when the lever is attached
Very good point! .. good catch!

The splined shaft has to be turned fully clockwise, then the arm installed with the split aligning with the line on the case. Might be the source of the extra slack, hope you didn't adjust yet.

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__________________________________________________ ____________
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post #9 of 54 (permalink) Old 01-17-2019, 06:12 PM Thread Starter
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Like this? I dont quite understand what nees to be done here

I gues I dont understand what you mean with aligning it with the case.

Edit: (The slack wasnt there before i got the cable off before i took the engine out.)
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Last edited by Panarock; 01-17-2019 at 06:52 PM.
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post #10 of 54 (permalink) Old 01-17-2019, 06:55 PM
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Quote:
Originally Posted by Panarock View Post
Like this? I dont quite understand what nees to be done here

I gues I dont understand what you mean with aligning it with the case.

Edit: (The slack wasnt there before i got the cable off before i took the engine out.)
No, thread that piece all the way back in for now.

Check this pic:



Take that clutch release arm back off the shaft. Rotate the splined shaft all the way clockwise, then re-install the arm, aligning the split in the release arm with the line on the case. Same alignment you have in this pic, but keep the shaft turned clockwise.

My mistake forgetting this step earlier.

Don't forget to put the bolt back in the clutch release arm.

2003-21k mi
Shaved w/UniPK92+Stock Jets-TPE/MOSFET-Shinko Tires-AGM batt-bags-chrome-LEDs...more
__________________________________________________ ____________
Repair Manual: http://www.mediafire.com/file/mj7z81..._Catalogue.pdf

Owner's Manual: http://www.mediafire.com/file/nscb5f...ers+Manual.pdf

Last edited by Spockster; 01-17-2019 at 07:02 PM.
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