Making your own Junction Box? - Page 2 - 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 #11 of 13 (permalink) Old 07-06-2019, 10:44 AM
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Originally Posted by HardRock View Post
Here's the thread that replaced the junction box with a home brewed fix.
How to Truly Fix the Vulcan's Electrical Problems https://www.vn750.com/forum/19-electrical/90426-how-truly-fix-vulcans-electrical-problems.html
I would really like to go back and put in some busbars to handle power distribution at certain points to reduce voltage loss where power splits off to mutiple places as well as clean the wiring up.

Engineer/Motorcycle Junkie

Junction Box Bypass:
https://www.vn750.com/forum/19-electr...-problems.html
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post #12 of 13 (permalink) Old 07-06-2019, 12:03 PM
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Has it been determined that the oem JB has anything to do with stator failure?

Since you don't have the bike yet, there are some other things you should be concerned about as well. Is it stock? Check the final drive splines and cam chain tensioners. The oem tensioners are defective, and when they fail, they will usually destroy the engine. If the final drive splines are worn down, that can be a VERY expensive fix, and it is fairly common. I would check these things before getting into the electrical. Hopefully the stator is good. Replacing the stator (and doing it right) requires the engine to be pulled. Best of luck with it.

I am a motorcyclist, NOT a biker.


1997 Vulcan 750, purchased about a week ago
2006 Sportster 1200 Low
2013 Royal Enfield Bullet 500, converted to carb
2001 Yamaha XT225, heavily modified
2004 Honda Rebel 250
1979 Vespa P200E
2002 Vulcan 750 parts bike
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post #13 of 13 (permalink) Old 07-11-2019, 10:32 PM Thread Starter
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Theres a video on YouTube where this guy totally rewires his bike with new wiring. He made it by taking the old harness out and laying it on a piece of sheet paper the length of the harness and drew a outline of it and wrote down which harness connector went to which part of the bike. Then he marked every wire and then had spools of wire and just started laying out the wires according to the old harness. Then he used New connectors on it and tightly put electrical tape around it. I think doing sonething like that, and using bigger wire and making sure that every ground wire is connected to unpainted metal on the frame along with rewiring the stator to a proper 10 or 8 gauge wire and take out the 3 thats usually on it. Along with a mosfet r/r would make the problems with the bike diminish greatly if not totally make them nonexistent when talking about anything electrical.

Last edited by Rollerzonly; 07-11-2019 at 10:58 PM. Reason: Finish the post
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