Concours Owners Group (COG) Forum

Concours Discussion (C10 / ZG1000 / 1000GTR) => Concours C10 / ZG1000 General Chat and Tech => Topic started by: charger_john on June 26, 2015, 07:23:56 pm

Title: C10 wiring diagram complete
Post by: charger_john on June 26, 2015, 07:23:56 pm
I have the clymer service manual for my C10. I have always been disturbed by the fact they have a separate wiring diagram for the junction-box (fuse box/relays), on a separate page, with no hard cross reference to the "main" wiring diagram. This makes it hard for me to understand the circuit functions.

So with much graphics effort and some reverse engineering I merged the J-Box wiring image data into the main wiring diagram. Here is a jpg of it. Perhaps other COG C10 owners will find it helpful.

Happy riding (and wiring),
charger_john in Kent, WA.

Title: Re: C10 wiring diagram complete
Post by: Pbfoot on June 26, 2015, 07:26:32 pm
Very cool.  Thanks!
Title: Re: C10 wiring diagram complete
Post by: who me? on June 26, 2015, 07:47:00 pm
Thanks :great:
I think Ill get this blown up to hang in the garage when I start sorting out the wiring
Title: Re: C10 wiring diagram complete
Post by: GF-in-CA on June 26, 2015, 07:51:35 pm
Thanks for doing this  :great:
Title: Re: C10 wiring diagram complete
Post by: robertv on June 26, 2015, 07:55:32 pm
This is great, thanks John! I have some other wiring I'm cleaning up as I added a relay switch and wanted to add some other farkles.  :great:

Title: Re: C10 wiring diagram complete
Post by: alan on June 26, 2015, 08:02:37 pm
Super! No more jumping from pic to pic = less thinking.
Title: Re: C10 wiring diagram complete
Post by: Outback Jon on June 26, 2015, 08:20:20 pm
So, where's the diagram for the pre-94 bikes with the Reserve Lighting Device?   :nananana:

Seriously, though, thanks for the work.  Looks good.
Title: Re: C10 wiring diagram complete
Post by: charger_john on June 27, 2015, 02:25:15 pm
So, where's the diagram for the pre-94 bikes with the Reserve Lighting Device?   :nananana:

Seriously, though, thanks for the work.  Looks good.

Maybe next time, outback.
Title: Re: C10 wiring diagram complete
Post by: Bucky on June 27, 2015, 04:43:31 pm
Thanks for that. Very helpful for an upcoming farkle wire campaign. (one of these damned days when I can make time)

Dumb newb question - (too lazy to walk out to the bike / lawnmower tent) -

One would think the wire colors of the diagram would match the wire colors on the bike itself? I would think so, but...

Had a thought to install a marine grade fused junction block I have kickin' around here somewhere into the plastic box above the battery with fat wire battery juice to it, then a hank of heavy gauge 5 or 7 wire trailer cable from the junction block to the front fairing area to feed assorted relays when the time comes. So far I'm thinking air horn, one or two sets aux lights, at least two cig plugs and I'm up to five, so I guess 7 wire would be the way to go, and make one of the 7 a dedicated ground. Maybe use a bolt up front for a ground lug and use the dedicated ground in the cable to get back to the battery - maybe. Now to find a less than 250' length of 7 wire cable. I have a loom all hot wire fetish, so the cable would eliminate some of the looming. :o
Sorry for the OT - coffee boy on the loose typing out loud again.
Title: Re: C10 wiring diagram complete
Post by: GeorgeRYoung on June 27, 2015, 06:35:54 pm
. . . I merged the J-Box wiring image data into the main wiring diagram. . .
Muchas Gracias.
Title: Re: C10 wiring diagram complete
Post by: Rev Ryder on June 27, 2015, 06:58:44 pm
So, where's the diagram for the pre-94 bikes with the Reserve Lighting Device?   :nananana:

Seriously, though, thanks for the work.  Looks good.

There's a great deal more different than just the RLD on the older bikes. Switching, J-box duties, etc. are different. I'm just saying that for early bikes, you/we still need your service manual and multiple pic jumping.  But this is the best wiring diagram I have ever seen for the post 93 ZG's.  Outstanding work!  This needs to be archived somewhere for folks.  I just made a color 11X17 print out and it's very, very nice.  KUDOS and THANKS!!!
Title: Re: C10 wiring diagram complete
Post by: GeorgeRYoung on June 27, 2015, 09:06:14 pm
. . . This needs to be archived somewhere for folks. . .
Rumour has it there is a wiki on this site.
Title: Re: C10 wiring diagram complete
Post by: WillyP on June 27, 2015, 09:18:06 pm
Nice, thanks for doing this.  :great:
Title: Re: C10 wiring diagram complete
Post by: Derick on June 28, 2015, 01:49:05 am


Had a thought to install a marine grade fused junction block I have kickin' around here somewhere into the plastic box above the battery with fat wire battery juice to it, then a hank of heavy gauge 5 or 7 wire trailer cable from the junction block to the front fairing area to feed assorted relays when the time comes. So far I'm thinking air horn, one or two sets aux lights, at least two cig plugs and I'm up to five, so I guess 7 wire would be the way to go, and make one of the 7 a dedicated ground. Maybe use a bolt up front for a ground lug and use the dedicated ground in the cable to get back to the battery - maybe. Now to find a less than 250' length of 7 wire cable. I have a loom all hot wire fetish, so the cable would eliminate some of the looming. :o
Sorry for the OT - coffee boy on the loose typing out loud again.

I did this as well, installed a blue sea 6 position fuse block under the right side cover. I spent like 60 bucks on it like 8 years ago..ridiculous. I just recently bought a regular old fuse block at oreily that is 10 position w/ ground that I intend on replacing it with. I think it will hold up just fine, and only cost about 20 bucks.
Title: Re: C10 wiring diagram complete
Post by: Derick on June 28, 2015, 01:50:19 am
I have the clymer service manual for my C10. I have always been disturbed by the fact they have a separate wiring diagram for the junction-box (fuse box/relays), on a separate page, with no hard cross reference to the "main" wiring diagram. This makes it hard for me to understand the circuit functions.

So with much graphics effort and some reverse engineering I merged the J-Box wiring image data into the main wiring diagram. Here is a jpg of it. Perhaps other COG C10 owners will find it helpful.

Happy riding (and wiring),
charger_john in Kent, WA.

I gotta ask...did you do this by hand?!?!? If so...nice friggin work. I mean, I would have scanned the kawi service manual for you had you just asked, saved that labor, but this is very nice if you authored it.
Title: Re: C10 wiring diagram complete
Post by: Outback Jon on June 28, 2015, 10:51:37 am
Dumb newb question - (too lazy to walk out to the bike / lawnmower tent) -

One would think the wire colors of the diagram would match the wire colors on the bike itself? I would think so, but...
Since it appears that charger_john used the Clymer manual as the basis for his diagram, the colors should match what is on the bike.  Thus far, everything on my bike has matched the Clymer manual colors when I've gone looking for a specific wire.
Title: Re: C10 wiring diagram complete
Post by: BobT_MA on June 29, 2015, 02:12:01 pm
Thanks for the great work you put into this wiring diagram.  My only question is where is the accessory connector that is suppose to be up front?

Bob T
Title: Re: C10 wiring diagram complete
Post by: charger_john on June 29, 2015, 03:10:57 pm
Thanks for the great work you put into this wiring diagram.  My only question is where is the accessory connector that is suppose to be up front?

Bob T

Accessory connector is shown on the left side of the diagram, just under the headlight.
BTW, my bike (2001) has another accessory connector just like it, under the seat, that's not shown on the diagram.
Title: Re: C10 wiring diagram complete
Post by: charger_john on June 29, 2015, 03:15:12 pm

I gotta ask...did you do this by hand?!?!? If so...nice friggin work. I mean, I would have scanned the kawi service manual for you had you just asked, saved that labor, but this is very nice if you authored it.

That would have been great having the kawasaki diagram!
I looked over this site and didn't find it. (actually found one part of it scanned
but not enough to help)
Some others had made comments about not posting copyrighted data......
So if you don't hear from me anymore maybe it's because I've been sent up.

But anyway, I got the job done in my spare time using the Clymer diagrams
and microsoft paint.

~ charger_john
Title: Re: C10 wiring diagram complete
Post by: charger_john on June 29, 2015, 03:20:28 pm
. . . This needs to be archived somewhere for folks. . .
Rumour has it there is a wiki on this site.

Yes George my diagram might belong in a wiki/knowledge base of sorts (if there is one).
I had to condense the file size a bit to get under the 350K attachment limit. If someone
out there has permission to post in a wiki, feel free to ask and I can e-mail the full
resolution version (798K).....
Title: Re: C10 wiring diagram complete
Post by: JeromeT on June 29, 2015, 04:35:09 pm
You are a scholar and a gentleman.

I have access to a large format printer, and I'd like to dump this out to something I can hang on the garage wall.  Any chance of getting a version of it that is about three feet wide?
Title: Re: C10 wiring diagram complete
Post by: BobT_MA on June 29, 2015, 10:30:44 pm
I meant where on my 86 C10 is that accessory connector?  Sorry for not clarifying my question.
Title: Re: C10 wiring diagram complete
Post by: WillyP on June 29, 2015, 11:17:45 pm
In the front, under the left inner fairing. Just forward of the left pocket.
Title: Re: C10 wiring diagram complete
Post by: Bucky on August 23, 2015, 04:56:37 pm
Forgive me if this is obvious

ctrl and + makes the diagram larger

ctrl and - smaller

ctrl and 0 (zero) restores it to original

The above works with most windows screens
Title: Re: C10 wiring diagram complete
Post by: Cap'n Bob on August 23, 2015, 05:32:18 pm
Thanks. I added it to my collection of schematics and such.   :great:
Title: Re: C10 wiring diagram complete
Post by: rickm_tx on August 23, 2015, 10:08:38 pm
Great job.

Thanks for taking the time and effort.  A lot of people are going to benefit from your effort.


Again, Thanks!
Title: Re: C10 wiring diagram complete
Post by: Jorge on August 24, 2015, 12:07:53 am
Really cool John.
Thank you!!
Jorge
Title: Re: C10 wiring diagram complete
Post by: C@nnothas on April 23, 2017, 03:29:43 am
I know this is an old topic, but I just spent over 2 hours searching the web for a C10 wiring diagram  >:(

This is the only one I found, and I want to say thank you for posting it.  This is going to be crucial for me to take on the project of turning this into a cafe racer  :motonoises:   :great:

EDIT:
I just spent an hour reviewing the diagram for better understanding, and noticed that the Starter Solenoid (at the bottom by the starter motor) is mislabeled as the "starter relay", which lives in the junction box.  I know, anyone who understands this diagram will just move on if they even see it, just wanted to say something in case it mattered to you.
:beerchug:
Title: Re: C10 wiring diagram complete
Post by: MAN OF BLUES on April 23, 2017, 07:50:54 pm
Well, technically speaking, an electrically actuated solenoid is in fact a relay, a non latching or more correctly a "momentary" contacting relay...
All is good,
 :great:
Title: Re: C10 wiring diagram complete
Post by: Lee on December 07, 2017, 02:40:07 pm
Thanks for posting this!
Title: Re: C10 wiring diagram complete
Post by: JimBob on December 07, 2017, 05:42:26 pm
Wow, nicely done!


So how much of this is re-creation on your part? LIke did you start totally from scratch? Because Paint isn’t exactly the easiest tool for this job. Even doing this in something like Visio would be MANY hours, and it’s a far better tool than Paint! You’re a bold man to take it on!



Title: Re: C10 wiring diagram complete
Post by: Redbarron on January 03, 2018, 10:00:08 am
Greatly appreciated John this will help all of us tremendously.