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Old 07-05-2010, 08:59 AM   #31
x3300 OP
geoff
 
Joined: Mar 2005
Location: San Jose, CA
Oddometer: 170
Sensor Harness

I've started to focus on getting the electrical system in order, which will be a fair amount of work in all. I've already got the voltage regulator harness done as reported in a previous post. I'll also need to rebuild the main and sensor harnesses, which will include some mods to each. The rear harness is in good condition, and I think I can use it as is with maybe some changes to the terminals for a different tail lamp and turn signals. The dash electronics need to be designed and wire up, and an overhaul of the bean can which has a sticky advance is needed. I haven't decided on the tail lamp and turn signals, but I do know I'll try to use LED units for those.

I needed to wire in an engine temperature sensor for the Trail Tech computer I have in the dash. I figured the cleanest way was to have the sensor lead run under the left carb and hook into the existing GS sensor harness then go up through the main harness to come out up near the steering head.

I took some measurements of the GS sensor harness and came up with this harness design diagram. The connector I used for the temp sensor between the sensor harness and the main harness is a Molex .062 2-pin connector.

http://stuff.gotdns.org/bike/orgs-build-up/19-sensor-harness/sensor-harness-diagram.jpg

Here is the stripped sensor harness, a Trail Tech temp sensor I'll use, and a Trail Tech V300-48 sensor extension cable. The extension cable isn't long enough to reach from under the carb to the steering head so I'll need to extend it with some wire in the main harness. For the sensor harness end I just cut it to the right length and soldered on Molex connector pins.

http://stuff.gotdns.org/bike/orgs-build-up/19-sensor-harness/stripped.jpg

Here's the finished sensor harness with a new connector for the oil pressure switch.

http://stuff.gotdns.org/bike/orgs-build-up/19-sensor-harness/done.jpg

I'll put the temp sensor under the rear left valve cover nut. I plan to hook up an oil temp sensor later.

-x3300
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