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@wulfband
SubscriberThe primary wiring connection was the flash unit that they had mounted inside the rear wheel fender. This was a major pain in the butt to get too so I moved it into the battery compartment. This took me almost 10 months but I wasn’t in any hurry. I found out that some of the wires they had connected weren’t doing anything and others were not routed properly. After research and tracing the wires to their primary connection I was able to get it all back together. I know I posted that I would try to put up a new diagram but I don’t think I’m going to be able too as I would have to retrace all the wires again. It’s not as difficult as I thought.
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@wulfband
SubscriberUPDATE ON WIRING DIAGRAM,
Most of the diagram is correct but what isn’t has to be traced by individual component to single out just what is going on. I found this to be the easiest way to configure the wiring.loop-single-reply.php
@venmc
AdministratorThanks for sharing… the background on the wiring diagram is classic chopper tale. In our first model year 2003 we started buying our harnesses from “Pops”. He was a southern California motorcycle mechanic/builder who made wiring harnesses for project bikes. He was well known in the local trade as the go-to guy if you needed to wire a bike. Pops had an industrial space in Colton, CA that served as his workshop and his home. These were simple functional harnesses that were handmade and delivered to us by Pops once a week.
It didn’t take long for us to get our first call from a dealer who was having an electrical short and he requested a wiring diagram. Pops refused to supply one. It’s not that he was unable to produce it… he was just unwilling. To a lot of bike builders and backyard mechanics, electronics were alchemy. Knowing how these worked made Pops special and kept him in-demand from local bike builders.
Also I firmly believe Pops was afraid that if we had a wiring diagram we would send it off to China and have someone else make them. So we did what any good customer would do. We took a harness apart and reverse engineered it. The wiring diagram posted here is the result of that project. For those of you with 03/04 bike that have the flash module bolted to the splash guard (sorry for that), this diagram should be correct. In mid 05 we started using the larger key box and moved the breakers and flash module components into the key box. This likely changed the wiring diagram ever-so-slightly but resulted in WulfBands observation that this drawing is “mostly” correct.
We bought every harness we ever used from Pops and he never gave us a wiring diagram. Pops passed in 2010 and his undocumented wiring diagrams have passed with him into the ether. There’s a reason that they are called Choppers.
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@wulfband
SubscriberInteresting, thanks for the info. When I reconfigured my wiring harness I quickly realized the many complications to do so and with any custom motorcycle they can all be different depending on the buyer and their accessories. It’s like you need a supplemental wiring diagram for every add on. This is really noticeable with big bikes like the Honda Gold wing that can be a real wiring night mare.
My research led me down a road of confusion and noticed that only big motorcycle manufacturers had a set wiring diagram that was anywhere correct and even some of those aren’t. I’m not complaining just noticing the lack of a serious professional approach to the subject. Plus on top of it all there is a serious lack of some of the colors of wires available and an endless amount of connections available. It’s enough to make your head spin. After a while I started considering going into business making custom order harnesses myself which are still available but very high priced and I can see why now.
My research led me down a wire investigation road that was pretty interesting. I met with owners of companies who supplied special wire that would have hundreds of different colors and sizes and different metals all in 1 cable. Even some of those owners admitted that they too had clients searching for specific colors that were unavailable so they would cut sections of these commercial cables and dismantle them just to get a specific color of wire. I ran into this problem with some of the colors on my Raider. So it seems that not all wire colors are always available or have to be custom manufactured and that would cost a pretty penny.
I come from a heavy electrical family, my father was one of the men who helped invent and introduce and implement the Norad Radar System. He had received tons of Presidential awards for his achievements. I was really proud of him. My uncle, my dads younger brother went on to be one of the head engineers at North American Rockwell and Douglas Aircraft. I keep twisting his arm on UFO info and when are they going to disclose that they have been making anti-gravity craft for a long time but he just smiles at me and doesn’t say a word. lol I just wish I was 1/2 as intelligent as either of these 2 guys were.
But with custom motorcycles and wiring harnesses it all seems to boil down to when you have a problem just trace it down and isolate it to fix it.
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@jmeals
SubscriberI’ve got another 3 Vengeance Vendetta and I’m having a problem with my LED speedometer my horn and my left side turn signals front and rear. I need any help and troubleshooting that I can get. I’m a novice mechanic and only work on a 49 Panhead and this bike; 03 vengeance. Email is jamesmills990@gmail.com
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@daniellea-hawley
Subscriber2006 teacher have to rewire ignition coil/ign circuit wires… But can’t seem to find accurate schematic
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@venmc
AdministratorThe ignition and coil are Crane… pull the cover and verify the PN on your ignition but this is the basic setup.
Last winter I had a short in my handlebars and found that the diagram was basically correct but still required me to trace the short back thought the harness manually. My bike had pull back risers added and the starter control wire had rubbed through and would randomly short. Your best bet to use the diagram as a guide but to trace the harness manually. Let us know what you find.
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@jack
SubscriberCan I get the link or copy of this diagram
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@venmc
Administratorloop-single-reply.php
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