Wiring

This to me is the most fun of the teardown.  Re-doing the wiring.  You can get 20-25 ft of colored 16-18 awg wire on amazon for 6 bucks.  So I am going to get a bunch of different kinds to re-do the wiring.  I am a Video Engineer so I work with low-voltage audio/video wire all day.  This will be fun.


Here is a before picture of what the block should look like (minus the brown wires)

First thing I did was make a simple diagram of the wiring block and the different wires coming and going from it.  This is the breakdown.  There are wires coming from the flywheel / points, and there are wires coming from the main trunk going to the Handlebars (horn, killswitch, lights, etc.)  We will refer to them as the "Handlebars" for now...


There are 6 colored wires coming from the flywheel / points.  They are as follows...


GREEN BLACK (Green with black stripe)
BLUE
YELLOW
GREEN
GRAY
BLUE BLACK (Blue with black stripe)


All but Gray and Blue/Black go to the wiring block.  Gray goes to a separate junction and then goes to the rear tail light.  Blue/Black goes straight up the main wire trunk up to the Handlebars.


On the other side of the wiring block, we will attempt to match up the colors.  I have attached a crudely made drawing of a wire diagram.  

So... You will have 7 wires going up the main trunk to the handlebars.  (2) Blue/Green wires, (2) Green wires, (1) Yellow wire, (1) Black wire, and (1) Brown wire.  A second Brown wire will go to the frame and act as a ground.  A Blue wire will come out of where the Black wire comes out and go to the coil.


Now that you know where everything is supposed to go, you can disconnect the wires from the wiring block, coil, and ground.

This is where the wires come out of the flywheel/points.

Again, once we take off the controls and handlebars, we will be able to get a really good idea of what colors hook up to what controls (horn, kill switch, lights, etc.)

More later...