Wire Harness Woes... - Kawasaki Vulcan 750 Forum : Kawasaki VN750 Forums
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Where does this wire go?
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post #1 of 14 (permalink) Old 04-27-2011, 11:38 AM Thread Starter
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Wire Harness Woes...

I have a 1987 VN 750 (A)

I have a short in my wire harness that causes me to lose charge when cranking my bike, melts electrical tape, and causes backfiring. I have peeled back the tape to reveal a very frayed black and yellow wire running most of the length of my harness. Am I better off to pull it off and change that bugger out or to just replace the harness outright?

I can see several places where it has been worked on before that remain very much intact and in good shape. However, two wires are often melded into one by the repair work that was previously done. Pics coming soon!

Thanks for any input! Ride safe!

Zach

Last edited by Mr_Grimm; 04-27-2011 at 08:33 PM. Reason: Update
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post #2 of 14 (permalink) Old 04-27-2011, 12:34 PM
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Check that the big cable to the frame and battery are clean and tight. Sounds like the full current is running throught that small wire and by passing the main ground cables. Check the one from the battery and the one from the engine to the frame.

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post #3 of 14 (permalink) Old 04-27-2011, 12:35 PM
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That's the ground wire.....It goes all over the place.... I feel your pain, that's why I rewired my entire bike...
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post #4 of 14 (permalink) Old 04-27-2011, 07:24 PM Thread Starter
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I already had a bad ground that I replaced b/c the loop that connects it to the frame broke. It was the main(?) ground. I even replaced the wire with a larger gauge. Maybe I missed something??

I found a working used harness from a parted out '87 VN 750 (A). It works but needs the connectors for the Rectifier. I can get that off of my harness. Look and see what you think! I just need to buy it ($32.00) and wire it in.

Here is the link...

http://www.maksbikes.com/index.php/k...ring-loom.html
Click image for larger version

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post #5 of 14 (permalink) Old 04-27-2011, 07:36 PM Thread Starter
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Quote:
Originally Posted by niterider View Post
Check the one from the battery and the one from the engine to the frame.
From the engine to the frame? Where is that one? I only repaired the loop of main ground wire going from the battery to the frame as pictured above. I can see that most of the ground coming from under the gas tank is frayed. I will pull that this weekend.
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post #6 of 14 (permalink) Old 04-27-2011, 08:04 PM
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What year is your bike?
The 85-87 models have a different wiring harnes than 88 and later.
Quote:
Wiring harness
- '85-'88 have a Turn Signal Control unit
- '89- up Turn Signal Control unit eliminated.

- '85-'88 are NOT interchangeable with 1989 and up
Won't work by leaving the signal circuit open
There is a ground wire coming off the back of the engine case that attaches to the frame.

Gordon

1991 VN 750 -"Cosmic Lady" or "Bad Girl"?
Purchased May 16, 2008
Approx.19,300km (12,000 miles)

H-D windshield
Relocated R/R
MF-AGM battery
Fiamm Freeway Blaster horns
F&S luggage rack and engine guard
Kury Offset Hiway pegs
July 13, 2016, Riding on the DARKSIDE now, Classic Radial 165/80-15


TOP TEN THINGS A NEW RIDER/OWNER SHOULD DO. Click on link.
https://www.vn750.com/forum/11-vn750-general-discussion/9127-top-ten-items-you-would-suggest-new-owner-do-his-new-ride.html
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post #7 of 14 (permalink) Old 04-27-2011, 08:32 PM Thread Starter
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Ooops! I knew I forgot something!

1987 VN 750 (A)
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post #8 of 14 (permalink) Old 04-27-2011, 08:36 PM Thread Starter
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Quote:
Originally Posted by OlHossCanada View Post
There is a ground wire coming off the back of the engine case that attaches to the frame.

Do you have a pic or a diagram I could see of this? I wasn't aware of that ground. I need to be able to check it. The battery/frame ground broke its connector loop. An easy enough fix... I upped the wire gauge as you can see in the pics.
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post #9 of 14 (permalink) Old 04-27-2011, 09:13 PM
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Quote:
Originally Posted by Mr_Grimm View Post
I already had a bad ground that I replaced b/c the loop that connects it to the frame broke. It was the main(?) ground. I even replaced the wire with a larger gauge. Maybe I missed something??

I found a working used harness from a parted out '87 VN 750 (A). It works but needs the connectors for the Rectifier. I can get that off of my harness. Look and see what you think! I just need to buy it ($32.00) and wire it in.

Here is the link...

http://www.maksbikes.com/index.php/k...ring-loom.html
Attachment 3688

Attachment 3691

Attachment 3692
pic one looks like the fuel sender..... pic three shows a factory splice. I see three yellow wires there..... does the stator wiring on your bike run way up there with the main harness??
Check for over-voltage... also check your main grounds....If they main grounds go, it leaves the smaller ones to take up the slack. I use a main ground wire from my battery to a ground block where all the other grounds meet.
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post #10 of 14 (permalink) Old 04-27-2011, 09:24 PM
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I don`t have a picture. I can reach in from the left side between the engine and the vertical frame rail to touch the bolt head and ring on the top rear of the cases. (There is not enough room for my hand to fit between the junction/fuse box and the frame.) The heavy ground wire/cable is screwed on where the left and right engine cases are joined. The bolt screws in from the right side. Not so easy to reach with my big mitts, but easy to see.

The cable is ~16-18" long and comes out the right side of the frame and is attached to the battery box with the front bolt, just in front of, and above the starter relay/solenoid.

Gordon

1991 VN 750 -"Cosmic Lady" or "Bad Girl"?
Purchased May 16, 2008
Approx.19,300km (12,000 miles)

H-D windshield
Relocated R/R
MF-AGM battery
Fiamm Freeway Blaster horns
F&S luggage rack and engine guard
Kury Offset Hiway pegs
July 13, 2016, Riding on the DARKSIDE now, Classic Radial 165/80-15


TOP TEN THINGS A NEW RIDER/OWNER SHOULD DO. Click on link.
https://www.vn750.com/forum/showthread.php?t=9127
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