Making my own TM150XRX harness

[wildbob]

So I hadn't heard back from any parts companies about a new harness for my TrailMaster (I'm sure Christmas/Holiday time is busy time for these folks), so I've decided to make my own The problem I'd been having is I'd been burning up ground wires (two harness so far) So in listening to other more knowledgeable members I've decided to put thicker gauge wires on the ground system. Here's what my current ground wire looks like.

[wildbob]

I ordered some connectors from electricscooterparts.com and started re-doing the wires. 14G for the wires (which looks to be thicker than stock) and 12G for the main ground.

[wildbob]

Old and new wires..

[wildbob]

So far the plan is to sheath the harness is flex conduit and seal it in heat shrink. I'm waiting on some of the other colors of primary wire (trying to keep the color codes the same) and a blade fuse setup to replace the stock fuse.

[wildbob]

One thing I'm curious about, because I'm a complete noob when comes to wiring is, how does the ground circuit ever actually reach "ground" with rubber tires and all. I'm sure there's a obvious thing I'm not seeing.

[liduno]

Ground is a relative term..lol

[Numbers]

What you are looking at is what I believe is called a floating ground. All that is needed to be classified as a ground is a return path for electric current. If it were connected to " earth " it could simply be called a ground. However, because it does not connect to earth but still provides a return path for electric current, it is called a floating ground.

[Numbers]

Oh... almost forgot. Great source for electrical parts is a place called Waytek.

http://www.waytekwire.com/products/

I'm not taking anything in return for their products, I always try to use what's here first but if you can't find it, they have it or can make it. Such as striped wire which you can order but it requires a minimum footage to be made. They have different styles of battery crimp connections, plastic wire connectors, insulated and non insulated connectors, etc... Order a catalog through them for free and take a look see at your own leisure what they have available.

[wildbob]

Got one on the way from Jersey Devil too to keep in the spare drawer

[wildbob]

Major brain fade... I forgot what plugs into what. I took photos, but must have accidentally deleted them... So.. Black wire from battery goes where? I have the wiring diagram so, I should be able to get all the other stuff plugged together, but for some reason I can't remember where the Neg wire from the battery went to.. I need more sleep..

[liduno]

In most cases the big black wire from the battery will go to either the frame or the engine block.

[wildbob]

Originally Posted by liduno

In most cases the big black wire from the battery will go to either the frame or the engine block.

Ha! Yes, I'm stupid and totally forgot..

[jmansracerocket]

looks good wildbob, keep up the good work!

[wildbob]

Update: The harness works awesome.