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 37 (permalink) Old 03-24-2019, 11:17 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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post #32 of 37 (permalink) Old 03-25-2019, 12:56 PM
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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 37 (permalink) Old 03-25-2019, 01:09 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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post #34 of 37 (permalink) Old 03-25-2019, 06:57 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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post #35 of 37 (permalink) Old 05-18-2019, 07:21 PM
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Quote:
Originally Posted by L2fish View Post
I just replaced mine realizing it was 90 percent of my problem. Bike would crank fine but no power to the coils. Would run the battery down trying. Learned to wiggle the key after a couple times. But eventually the bike would cut out and run while riding.
you are my lost soul....lol I am having the same issue I'm gonna keep reading now..lol
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post #36 of 37 (permalink) Old 06-03-2019, 05:53 PM
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12 volts. at relay with switch off? 0 volts when turned on. is relay bad or is it my ignition switch?? no dash lights?? please help??

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post #37 of 37 (permalink) Old 07-06-2019, 11:15 AM Thread Starter
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I got a PM about the relay wiring, but it just disappeared somehow. I'll post info here:

Adding a relay to the headlight system is pretty straightforward. You can incorporate the removal of the reserve lighting unit or keep it in place. The pin layout is as follows:

Pin 85: Black/red (may be solid black on some bikes) or yellow/red from the starter solenoid circuit, tap into this circuit
Pin 86: Ground to frame or a ground junction within harness
Pin 30: Blue wire from junction/fuse box
Pin 87: Empty
Pin 87a: Blue wire to reserve lighting unit (same as pin 30, just interrupt the wire with this relay), or use blue/yellow or blue/orange from the reserve lighting unit removal article, mine needed the blue/orange

On my bike the black/(red) and yellow/red are soldered together after removal of the junction box, so I added a wire to that junction to trip the headlight relay. For the ground I peeled back some the of tape around the harness and found a crimped junction of ground wires and used that. You could just run an eyelet connector to the frame around the battery box.

For the ignition relay there is a junction of 4 red wires when peeling back the harness that you can see in my original post. You'll have to snip here and find out which one comes from the handlebar switch (it will have 12V with the key on). The remaining 3 wires will be powered by the relay:

Pin 85: Red wire from handlebar switch
Pin 86: Ground to frame or a ground junction within harness
Pin 30: White wire from junction/fuse box or new wire from battery with inline fuse
Pin 87: Red wires feeding coils and igniter box
Pin 87a: Empty, switch wire from 87 to here if relay fails or you lose power/ground from pins 85 or 86

Finally, the radiator relay pin-out. I haven't actually finished mine yet, but here is a guideline:

Pin 85: Self powered, split off of 30
Pin 86: Black/yellow wire to thermostatic switch
Pin 30: White wire from junction/fuse box if you want the fan to operate with key off to cool off radiator more, brown/white wire if not
Pin 87: Blue wire to radiator fan
Pin 87a: Empty, or just use a 4 pin relay

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