Reverse Engineering wiring issues on a used bike (Pictures and Details) - Kawasaki Vulcan 750 Forum : Kawasaki VN750 Forums
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post #1 of 10 (permalink) Old 10-06-2014, 05:57 AM Thread Starter
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Reverse Engineering wiring issues on a used bike (Pictures and Details)

Hey guys,

I recently picked up an 87 Vn750A from a buddy of mine.

He bought it off a guy in a city about an hour over, bout a year ago.
One of our mutual friends wanted to purchase the bike from him, but
the deal kinda fell thru. Stayed out of that. Ended up picking it up and
got a good deal on it.

Real happy with the bike, but its got some quirks. One of them being
that the headlight does not work. I have spent many hours researching
online, on this forum, and tinkering with the bike.

What I have found so far:

The 3 yellow wires coming out of the stator on the left side of the bike
were NOT plugged into the wire harness. The wires had quick connects
on them and they were unplugged. I am not sure if it is supposed to be
like that or not.

There actually IS a mosfet r/r installed on this bike. It is mounted under
the junction box, and has six wires coming out of it, that are spliced into
the wiring harness.

I have basically been taking this bike apart, tracing wires and getting to
know it. I currently have 2 main questions.

1) Should the 3 wires coming from the stator be disconnected from the
bikes wiring harness? The Mosfet is spliced into the harness but I am not
entirely sure how that works and affects the rest of the system.

2) How can I get the darn headlight working? I have read about splicing
a wire from the mosfet into the yellow relay wire from the 10 pin connector
on the junction box, moving the blue wire on the junction box connector to
the empty plug, etc etc.

I am thinking moving the blue wire so that the headlight comes on as soon
as I turn the key would probably be what I would like to do, but Im not sure
if it is the blue wire in the 10 pin connector on the junction box or the 8 pin
connector. Also since this guy moved a bunch of stuff around already, It
would be awesome if someone could supply a picture of the connector or a
pinout of it so I could check if the wire has ALREADY been moved.

ahhh, the joys of a pre owned bike haha. Despite the headaches Ive actually been enjoying this puzzle and am glad that I will know it inside and out.

------------------------

Here you can see how the wires from the stator are disconnected from the
harness. I assume they should be connected, but not sure. Halp.



Here you can see the junction box. Would the whole blue wire swap thing be
the top 8 pin connector or the lower 10 pin connector?



How she sits currently. Cant wait to get the kinks worked out and put her on
the road.



Thanks for your time guys!

[SIZE="4"][B]"A ship does not sail on yesterday`s wind."
[I]-Louis L'amour[/I][/B][/SIZE]

Last edited by MadKat; 10-06-2014 at 08:44 PM.
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post #2 of 10 (permalink) Old 10-06-2014, 07:27 AM
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Plug them wires in bro. As for the headlight wiring...I'm sure someone who knows will chime in.

2003 vn750
1988 Pontiac Trans Am (project/driver)
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post #3 of 10 (permalink) Old 10-06-2014, 07:04 PM
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that's not a mosfet r/r its a stock r/r

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Sucks getting old but it beats not getting old.

i got my helmet but it sure makes licking the windows a chore

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post #4 of 10 (permalink) Old 10-06-2014, 07:24 PM
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Aren't the mosfet r/rs a direct plug and play? Wouldn't that use the factory plug as displayed? As far as the actual r/r...can't see it the pic is too dark.

2003 vn750
1988 Pontiac Trans Am (project/driver)
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post #5 of 10 (permalink) Old 10-06-2014, 07:31 PM
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Quote:
Originally Posted by M_Angell View Post
Aren't the mosfet r/rs a direct plug and play? Wouldn't that use the factory plug as displayed? As far as the actual r/r...can't see it the pic is too dark.
nope here is a link to a mosfet for our bikes

http://www.ebay.com/itm/SHINDENGEN-M...c15b45&vxp=mtr

Quote:
Originally Posted by denny6006 View Post
Sucks getting old but it beats not getting old.

i got my helmet but it sure makes licking the windows a chore

cell phone number for anyone who needs it 214-516-1738

photobucket link
http://s1066.photobucket.com/user/newrider9984/library/
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post #6 of 10 (permalink) Old 10-06-2014, 08:48 PM Thread Starter
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Thanks for all the advice guys. You guys have cleared up a lot.

I come from a Harley background, so this is a whole new world to me hahah.
Im loving this bike though. A lot of the construction is not overcomplicated
like with the Harley, and the parts are dirt cheap in comparison.

I think I may have missed something obvious. When I get home from work Im going
to try plugging in the three stator wires and then starting the bike, and see if the
headlight comes on. I have already doublechecked the fuses, I think the stator not
being plugged in and the bike not being turned on is what was missing.

Thanks for your patience and advice! I will report back.

Oh, also! Should I look into replacing the stock R/R with a mosfet? Id assume yes..

[SIZE="4"][B]"A ship does not sail on yesterday`s wind."
[I]-Louis L'amour[/I][/B][/SIZE]
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post #7 of 10 (permalink) Old 10-06-2014, 09:06 PM
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yes I would or at least move the stock one from original position to a cooler location as to make it last longer

Quote:
Originally Posted by denny6006 View Post
Sucks getting old but it beats not getting old.

i got my helmet but it sure makes licking the windows a chore

cell phone number for anyone who needs it 214-516-1738

photobucket link
http://s1066.photobucket.com/user/newrider9984/library/
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post #8 of 10 (permalink) Old 10-07-2014, 09:12 AM
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With the stator disconnected the headlight (as stock) will not work. It relies on the stator to trigger the relay that runs the headlight.
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post #9 of 10 (permalink) Old 10-12-2014, 07:47 AM Thread Starter
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Evening Gentlemen!

Sorry it took me a bit to get back to yall, I work nights so my schedule is a bit screwy.

The pencil pushers decided we deserve a day off (normally work 6-7 days a week, so
every once in a while they say hey! stay home saturday!) so I spent most of the evening
in the garage.

So as for the headlight, there were a few layers in the issue.

1) there was a fuse that LOOKED good but was actually bad.
2) the stator was disconnected from the wire harness for god knows why
3) after fixing those issues, I attempted to test the headlight and still had no luck.
I later found out that this was because, gasp, the relay wasnt being triggered because
the bike was not on. I have been doing most of my work at night, as thats when I am
awake, and I went out one morning when my roommates were all awake and fired her
up and bam, headlight!

Funny story about the stator. My buddy was supposed to sell this bike to a mutual friend
of ours, and the deal kinda fell thru because the guy who was going to buy it went on a
bender and.. yea long story.

So I bought it from my buddy instead because I wrecked my Harley and wanted a project.
The guy who was supposed to buy it before me swore up and down that the battery was
dying by itself, and we all just heckled him over because the first day he had it he left the
key in the on position and drained the battery. Looks like he wasnt crazy after all, because
with the stator disconnected.. well yea!

[SIZE="4"][B]"A ship does not sail on yesterday`s wind."
[I]-Louis L'amour[/I][/B][/SIZE]
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post #10 of 10 (permalink) Old 10-12-2014, 07:54 AM Thread Starter
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So I got in there tonight and had all kindsa fun. I tore out the battery box, which was a rusted mess, and the wires were a straight rats nest. I cleaned up everything a bunch, sanded a lot of areas to remove rust and hit em with a rattlecan of high temp flat black.

I will be repainting the frame, tank, fenders etc within the next few months so I was more just doing spot cleaning and prep than anything seriously intended to look good. However I did sand down the battery box cage thingy and spray it up nicely, and then I organized up all the wires and got in there with zip ties and electrical tape to tidy it all up.

Looks a lot better under the seat now and I am very happy with it. I will be be getting in there again within the next month as I am going to be slapping a new seat on and installing new turn signals and a few other things here and there.

While I was at it, I pulled the R/R that was mounted to the battery box. In case anyone was curious what it was (I was) its an SH555-12.


[SIZE="4"][B]"A ship does not sail on yesterday`s wind."
[I]-Louis L'amour[/I][/B][/SIZE]
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