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Enduro Electrical & Wiring Lighting, Ignition, Wiring, Plugs, etc.


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  #1  
Old 07-16-2018, 04:20 PM
jjacks jjacks is offline
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Join Date: Jul 2018
Posts: 12
Default 2007 FSR 450 advice on electrical stuff

Hello everyone,
I'm new to Gassers and to the forum as well. I haven't found any landing/welcome thread therefore I am welcoming everyone in this very thread.
I got myself the FSR450 off an auction and it turned out to be a "project" bike.
https://photos.app.goo.gl/appGH4Q2Uxse9fyE6
I need to put some blinkers and horn on it in order to get it plated in my place, but once I started to looking for an indicator / horn wiring i found some interesting things tugged behind the headlight

https://photos.app.goo.gl/rkaS288SL9PHvKX68

Some issues are trivial and others are not, I want you guys to quickly run you through the stuff that concerns me.

Starting from a trivial thing: what is a stock headlight bulb on the FSR? PO forced the H4 bulb into the headlight but it does not fit...

I found 3 loose connectors with no apparent function in the loom behind the headlight:
https://photos.app.goo.gl/w9NEQkg5NCAbbQDh8
https://photos.app.goo.gl/Yx3yd6PVQCKdCjJk6
https://photos.app.goo.gl/aJGBZUmWriyZgZDu9

I also realized that killswitch is not connected at all (from the factory) and the ignition wires are soldered straight to pins:
https://photos.app.goo.gl/FzsH4bYZ9KseNYvg9
Does it come from the factory like that?


Then I have an Accuwell multi-function display. Does it have any backup battery inside? I could not find any - it seems like a sealed non-serviceable device. It does not keep historic measurements: avg speed, rpm, max rpm etc. Everything goes back to default values on every single turn of ignition. Is it expected? I think it is not.

Then there are blinker/lights indicators which are not connected at all and their connectors are wrapped with a heat shrink. Looks like they were never connected (not surprising since bike never had indicators).
https://photos.app.goo.gl/WrBC5VKVFjpek41f9
Any idea where to connect these?

I also noticed that the bike idles at 1900RPM which seems to be a bit high (regardless whether cold or hot).

Then I have a broken stator - there is no AC voltage on one of three coils (the other 2 generate 5-6VAC). The rectifier might be okay since it does try to produce 12VDC out of these 2 coils that still work. it is too weak to keep the battery charged but still better than unplugger rectifier. Unfortunately the workshop manual does not cover the stator removal at all. What tools beside the usual spanner set will I need to get it out?

There is also a rear blinker plug of a weird shape
https://photos.app.goo.gl/rMjEz92G91SjYmi36
Do you know the name of that connector or the place to get a matching one?

I am sorry if it is a bit chaotic, but it's 11PM and I had a pretty busy day today.
Should i split it into separate threads perhaps?
Cheers,
Greg



Last edited by jjacks; 07-16-2018 at 11:07 PM.
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  #2  
Old 07-31-2018, 02:32 AM
jjacks jjacks is offline
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Join Date: Jul 2018
Posts: 12
Default

Hi,
I will share some answers I found on my own.

https://photos.app.goo.gl/w9NEQkg5NCAbbQDh8 is blinker relay/intermittent connector (mate-n-lock universal)

https://photos.app.goo.gl/Yx3yd6PVQCKdCjJk6 is main connector with most of the signals on it including headlights, indicators, fuel gauge etc. Useful for dash indicators.

multi function manual and wiring is available here http://www.acewell-meter.co.uk/User%20Manuals/index.htm (ACE-38XX). Mind that wire colors may vary.

1900RMP idle is fine.

[https://photos.app.goo.gl/rMjEz92G91SjYmi36] this is a Molex connector - matching one is p/n 03-09-1032 https://www.molex.com/molex/products...P_HOUSINGS.xml
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