How to Truly Fix the Vulcan's Electrical Problems - Page 4 - 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 #31 of 34 (permalink) Old 03-24-2019, 10:17 PM Thread Starter
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Update: I did some work to the Vulcan over the weekend. It started as replacing the coils and turned into adding relays and making some repairs.

The wire to the thermostatic switch was broken internally, so I peeled back some of the wiring harness and replaced the broken section. Also, I was having issues with the motor spinning slow so I removed some powdercoating on the frame and made a good ground. It now spins twice as fast.

Next I deleted the reserve lighting device which led to wiring up some relays to power the radiator, headlight, and ignition system. The radiator and ignition relay wiring is pretty straightforward. The real trick thing I did was use a 5 pin relay and hook up the blue/yellow wire that used to be the output from the reserve lighting device to terminal 87a, so now the headlight turns off while the starter is turning over. Pretty cool, eh? I also used a 5 pin relay for the ignition so if the relay ever fails I can move the pin from 87 to 87a and hobble it home.

Attached is the mockup for my relay panel and fuseblock. Iím going to look for some better fuseblocks to make for a more robust design. Iím also going to move the r/r to where the goatís belly was originally mounted.

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Junction Box Bypass:
https://www.vn750.com/forum/19-electr...-problems.html
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post #32 of 34 (permalink) Old 03-25-2019, 11:56 AM
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I've been mulling over that headlight mod for a while now. Did you wire the new relay in series or parallel with the starter solenoid? How much digging in the harness did you have to do to make that happen?

1992 US-nonCA * tuxedo mod * r/r relocated

Vulcan slang for newcomers
Service Manual Download
Wiring Diagram + annotations * still undergoing revisions, but still more useful than the generic one. Let me know if you find mistakes or think something additional should be added
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post #33 of 34 (permalink) Old 03-25-2019, 12:09 PM Thread Starter
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I wired it in parallel. I had already peeled back the harness where it splits off to go to the tailights and rear turn signals and bypassed the old headlight relay in the junction box so I just added a wire at the junction of the black/red and yellow/red wires I made previously and ran it to the new relay.

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https://www.vn750.com/forum/19-electr...-problems.html
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post #34 of 34 (permalink) Old 03-25-2019, 05:57 PM
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Quote:
Originally Posted by mcinturff View Post
I wired it in parallel. I had already peeled back the harness where it splits off to go to the tailights and rear turn signals and bypassed the old headlight relay in the junction box so I just added a wire at the junction of the black/red and yellow/red wires I made previously and ran it to the new relay.
Cool. I'll add that to my to-do list.

1992 US-nonCA * tuxedo mod * r/r relocated

Vulcan slang for newcomers
Service Manual Download
Wiring Diagram + annotations * still undergoing revisions, but still more useful than the generic one. Let me know if you find mistakes or think something additional should be added
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