Wiring an old benelli

[steven c]

 This Winters project is to get my Benelli 2c electronic running, one of it's big issues beside low compression in both cylinders is the lack of a wiring harness and parts to power the lights and horn. Can someone point me in the right direction to figure how to come up with a lighting circuit?

[Kiwi_Roy]

Instead of trying to fond the correct colours for the loom might I suggest you make every wire black then identify the conductors using short lengths of white heat shrink marked with an indelible pen. This is what I did on my old loop.
You can mark the labels using the wire code from the diagram
you can wire each circuit just as you need it to work sketching it out as you go.
On my loop I have 3 fuses and a couple of relays, if a fuse blows a light turns on to help troubleshoot
I didn't use the original wiring termination panel but made a new one using a thin cutting board with small bolts to terminate the wires on.
One of Greg Benders harnesses is the Cadilac way to go

[steven c]

keyboard generator

[steven c]

I like the Greg Bender Harness. I should have mention the whole charging system is a mess and the stock system isn't that great. I did read where someone made up there own upgrading it.

[steven c]

Not sure if the Bender sub harness would work it's for the disc version mine had drums but I put a disc front end on it. Wiring is not my strong suite.

[TOMB]

Steve, looking at the picture you attached above, what could go wrong?

TOMB

[Old Jock]

Roy's idea (as usual) is first class. If you want to save cash it's a great idea, I did something similar wiring a buddy's V7 Racer I used cable markers but heat shrink would be even better. I've also went down the different colours route too doing another rewire and still have loads of cable left over.

Lights and Horn should be relatively straightforward, the only decisions being are you planning to use relays and if so for what, or not.

I'd use Thinwall cable 1mm^2 for low current and 2mm^2 for higher current, Thinwall can support higher current ratings than normal PVC and (at least in the UK) is around the same price

Just what I'd do 

[Canuck750]

British Wiring - www.britishwiring.c om
USA supplier of every imaginable wire colours for building new wire harness for cars and motorcycles, buy only the lengths you need, no order too small. They sell crimp on connections just like the originals. I have bought from them for years. Get the correct crimp tool and your ‘new’ harness will be exactly like the original.

[Cam3512]

If you send Greg your old wiring harness, he can duplicate it exactly. He can also add anything onto it that you might need. He did that for me with a Ducati scrambler I restored several years ago..

[steven c]

Thanks for all the advise. Looks like in the jumble of wires I have a relay of some sort and a rectifier a fuse with something mounted next to it that will have to be replaced.

[Scout63]

Instead of trying to fond the correct colours for the loom might I suggest you make every wire black then identify the conductors using short lengths of white heat shrink marked with an indelible pen. This is what I did on my old loop.
You can mark the labels using the wire code from the diagram
you can wire each circuit just as you need it to work sketching it out as you go.
On my loop I have 3 fuses and a couple of relays, if a fuse blows a light turns on to help troubleshoot
I didn't use the original wiring termination panel but made a new one using a thin cutting board with small bolts to terminate the wires on.
One of Greg Benders harnesses is the Cadilac way to go

I’ve wired in multiple colors, but since I’m bad at taking notes it doesn’t really help. God help future owners of my G5 Motogadget system.  I would keep all ground wires a separate color, maybe brown, and positive battery and regulator leads red.

[steven c]

 I would like to put together something like this. Just need to figure it out.