This is an attempt to rebuild these worn out old wiring harnesses with something new and improved. I’ll work it out, detail it to the best of my ability and then try to start selling them. Everything will be available for you to source and build your own from this page.
This is the open and decentralized way we keep these machines going and maybe even build an open source version.
I brought the 05 Raptor up from the basement (where there are tons more) to start on the wiring harness.
My goal is a complete wiring harness, fresh and high quality, fully documented with sources (affiliate links). I’ll build this post, turn this into a video and then build a course with everything needed to diagnose, repair or build your own – or – find someone that will.
I took some motorsports wiring courses at HP Academy and this is my first practical attempt to learn by using this Raptor. These machines are old and worn out and they are awesome when running correctly. They are also simple and therefore easy to learn on. Electrical issues and fasteners are the big challenges that I see and this is my attempt to cure this part of the quad flipping gig. Well organized replacements ready to go.
This is gonna be sloppy for a while as I’m working live with this page. I do have a Discord, but I keep it quiet while I’m working.
There will be affiliate links used.
I will be working on fastener kits and have those available at some time also. This is all just an attempt to be able to flip these things. We need to be able to source all these things because they are old ATV parts and they are trashed.
Klein CL390 multimeter and the Lisle 82650 Multimeter Accessory Kit for backprobing.
Ebay: 3 Pin Round Stator Rectifier Connector Set 1/4″ 6.3mm BigRed FourTrax SportTrax
Blender
I’m modeling every piece of this project in Blender, with all the 3D files free to grab from our Nextcloud hub at hub.steelbak.com. The mission? To figure out how to turn this Raptor 660 wiring harness into a fully open-source machine, backed 100% by the community market. Want to help shape it? Hit up our Discord, join the hub, and let’s build something badass together!
I forked CAD_Sketcher and installed it on Blender 4.3.2. Next, I’ll bring that into Cursor and see what’s up there. The website is cadsketcher.com if you want to see more. I support this project on Patreon.
The Plan
1. Analyzing the OEM Wiring Harness
- Disassembly and Inspection: Carefully disassemble the original harness to understand its layout and components. Document each connector, wire gauge, color coding, and protective coverings.
- Schematic Reference: Utilize the official Yamaha service manual for the Raptor 660, which includes detailed wiring diagrams. This will serve as a blueprint for your harness design. Quads
I have the harness on my bench, which I want to turn into a full harness building bench on casters for full access. I will measure everything and have all the pictures of how it all goes on the machine.
2. Sourcing Components
- Connectors and Terminals: Identify each connector type and source high-quality replacements. For instance, specific connectors like the 3-pin round stator rectifier connector can be found on platforms like eBay.
- Wires: TXL
- Protective Materials: Use durable loom tubing, heat shrink tubing, and protective wraps to shield the harness from environmental factors.
3. Building the Harness
- Tools and Equipment: Invest in quality tools such as wire strippers, crimpers, soldering equipment, and multimeters to ensure precision and reliability.
- Assembly Process: Follow the documented layout, ensuring all connections are secure and meet or exceed OEM standards.
- Testing: After assembly, test the harness for continuity, proper voltage, and load handling to ensure functionality and safety.
4. Documentation and Content Creation
- Visual Guides: Capture high-resolution images and videos during each step of the disassembly and assembly process.
- Written Manuals: Create detailed guides that include parts lists, tools required, step-by-step instructions, and troubleshooting tips.
- Platform Utilization: Share this content on your website, Steelbak.com, and consider creating supplementary video tutorials for platforms like YouTube to reach a broader audience.
5. Sales and Distribution
- Product Offerings: Offer fully assembled harnesses and kits containing all necessary components for DIY enthusiasts.
- Affiliate Marketing: Include affiliate links for tools and components, providing value to your audience while generating additional revenue.
- Quality Assurance: Emphasize the quality and reliability of your harnesses, highlighting the use of premium materials and meticulous craftsmanship.
6. Community Engagement
- Feedback Loop: Encourage customers to provide feedback and share their installation experiences, fostering a community around your products.
- Continuous Improvement: Stay attuned to customer input and industry developments to refine your products and expand your offerings.
Electrical Tests:
This is initially sourced from the Clymer Manual for the Raptor 660R 2001-2005
Chapter 9
Which of these can be done on the bench?
- Starter relay: Fuses
- Ignition coil and spark plug cap
- Pickup coil
- Rotor rotation direction detection coil
- Ignition timing
- Battery voltage loaded
- Battery voltage unloaded
- Regulator/ Rectifier output voltage
- Stator charging coils
- Fan system
- Circuit breaker
- Sending unit
- Water temp warning
- Circuit Diode
- Indicator circuits
Materials
Add a super capacitor to help the battery during startup?