Wiring Harness

jddelrosso · Post by **jddelrosso** » Wed Apr 13, 2011 4:02 pm

After recently acquiring a Dream I was able to free the engine with the help of the great people of this forum. I am now looking to refresh the wiring and make some changes along the way. My ignition cylinder was drilled out and I need to wire in a replacement as oem are difficult to find and expensive. So before purchasing wire and parts I have a few questions. What size wiring would be best for the bike. Looking at some charts 18ga looks like it should handle just about everything outside of the starter. Is that a safe assumption? On top of that having read some of how the electronics work on this bike what would have to be done to achieve full charging all the time as I will loose the 6 positions of the oem switch. I think those are my main concerns to a rewire of this bike. All help will be greatly appreciated.

brewsky · Post by **brewsky** » Wed Apr 13, 2011 6:11 pm

Welcome to the forum....where are you and what year is your Dream?

Here is the place to start on the wiring questions:
http://www.honda305.com/forums/viewtopic.php?t=6088

The most important thing you will note is there is no voltage regulator, so if you run unbalanced from original design you will either overcharge or undercharge the battery.

The ignition switch activates an extra coil in the magneto when in the "lights on" position, thereby adding extra juice for the lights. So if you hardwire it on all the time make sure you run the lights also or you could cook your battery.

jddelrosso · Post by **jddelrosso** » Wed Apr 13, 2011 7:32 pm

Brewsky,

My dream is a 65+ though i have not yet narrowed down the year

I know I have not filled in my profile but I am in NY where headlight needs to be on 100% of the time so I plan to hard wire it on with the key.

I have been staring at the wiring diagram for a while now. My current wiring is pretty messed up and I am decent with wiring so I figured I would run new for most of it.

How would I go about activating the other coil in running a new wiring harness? I will spend more time looking at the harness with the switch diagram and see if I figure anything out. Any more help would be greatly appreiciated

Jeremy

brewsky · Post by **brewsky** » Thu Apr 14, 2011 4:17 am

Jeremy, you will get a lot more response if you go ahead and fill out your location in your profile.

Connect the yellow and pink wires out of the magneto (AC Dymo) together for max output.
These are DY and SE terminals on the switch.

Post some pics when you can

brewsky · Post by **brewsky** » Thu Apr 14, 2011 4:28 am

It would also be a good idea to replace the rectifier.

Here's what can happen to an old one:
http://www.honda305.com/forums/viewtopi ... ight=smoke

jddelrosso · Post by **jddelrosso** » Sat Apr 16, 2011 9:19 am

Thanks for the info Brewsky

I was thinking that connecting those 2 wires would do it and I will be going that route.

I found this webpage http://www.mopedarmy.com/forums/discuss ... 229688&v=f which shows how to wire up a scooter regulator / rectifier which I have found all over ebay for under 25 bucks. Rather then going the radioshack route do you think this may work to fulfill the regulator portion of your earlier concern?

Let me know what you think

brewsky · Post by **brewsky** » Sat Apr 16, 2011 11:57 am

I'm not versed enough in the regulator department to make that call.

I don't see anything as to capacity of the ones in the link.

Maybe E3Steve can shed some light?

I would contact this guy before I tried to design or adapt one on my own.
http://www.oregonmotorcycleparts.com/vregulators.html