2004 Wire Plus Pre-Install
This is an attempt to help those 2004 Dog Owners that are patiently waiting on their wire plus kits, to get back on the road, but without turn signals, horn, or high-beam. The tach, speedo, and oil light will work. Brake lights, low-beam and running lights will work. Run/Stop switch will not function, only function on bar controls is start button and front brake switch. You must turn on/off engine and lights with key switch.
You can do this and ride now, then when your Wire Plus comes in, just take out the start and brake relays and you’ll already be halfway finished.
Some of the connections in the wire plus installation do not connect to anything and others do not connect to the wire plus modules, they just get connected to each other, so you can go ahead and do these while waiting (costs a few dollars for ring terminals and some wire that are included in the wire plus kit) and get a jump on installing the wire plus when it comes in.
And for a few more dollars and a little time you can get back on the road, just without turn signals, horn, or a headlight high beam.
If you can install a wire plus on your Dog, YOU CAN DO THIS.
Because the hand controls can’t handle more than 250mA at 5VDC (1.25 watts) we can’t run anything with them directly that will use more than 100mA at 12VDC or 1.25 watts. So we have to operate a bigger relay (which draws 5 watts on coil side) with a smaller relay (which draws 1/3 watt) that is operated by our hand controls. Easy as pie almost (maybe easy as Algebra).
The relays have 5 pins (or blades), two pins for the coil (that operates the relay), a common pin, a normally open pin, and a normally closed pin. The larger relays can use a plastic socket or female spade connectors and both connectors and relays are readily available at your local auto parts store. The smaller relays will probably have to have the wires soldered on them and can be readily found at your local electronics store like Radio Shack.
You will need :
- One - 40 amp 12VDC start relay - the big square kind like this one 12V DC Bosch Style 20A/30A Car Auto SPDT Relay Harness | eBay
- One - 20 or 30 brake amp 12VDC relay - the big square kind, Harness is optional but if you don’t get the harness you will need the female spade connectors to hook it up.
- Two each - 1 to 10 amp 12VDC relay. Any small relay that draws less than 100mA on the coil and has contacts rated for at least 1A will work. - like this one Mini 12V DC Power Relay (10A/125V AC, 7A/250V AC) 2pcs | eBay
- A 3 position (non-spring return) key switch that you can use for your wire plus install also. It will have a common pin, ignition pin, and a lights pin.
- 1 each – Inline 40 Amp fuse holder with fuse (can be blade or buss type) preferably water proof.
- 2 each – Inline 20 Amp fuse holder with fuse (can be blade or buss type) preferably water proof.
- 6 each – 12 or 14 gauge butt connectors.
- 6 each - 12 or 14 gauge ring terminals to fit your battery bolts.
- 6 each – 20 gauge ring terminals to fit your battery bolts.
- 3 each – 20 gauge connectors to fit your new key switch.
- 5 feet – 14 gauge wire (black)
- 8 feet – 20 gauge wire (red)
Ok, look at your WP374 2004 only wiring diagram and read the WP374 installation instructions.
Grounds: The instructions say to start with grounds, do them first. See Wire Plus instructions #13.
Disconnect positive side of battery while working on hooking up all the grounds.
All black wires attached to the EHC plug are grounds. Each one is used with the exception of the black wire at 2004 EHC position #38 (ignition switch ground).
- Group the ground wires in the main harness going to the front in one 14 gauge butt connector under the tank. Run a 14 Gauge black wire from the other side of this butt connector to a ring terminal at the negative(-) side of the battery.
- Group the wires going to the rear in another 14 gauge butt connector under the seat or side cover (whatever works best for you). Run a 2nd 14 Gauge black wire from the other side of this butt connector to a 2nd ring terminal at the battery.
- The horn and any additional black (ground) wires go in a third butt connector. Now run a 3rd 14 Gauge black wire from the other side of this butt connector to a 3rd ring terminal at the battery.
After you get
ALL the grounds routed and terminated and you are damn sure they are securely crimped or soldered, disconnect them from the battery to work on the positive wires.
Key Switch: Install the new 3 position key switch. Run a 20A fused 20 gauge red wire from the positive side of the battery to the key switch common pin (power supply).
Ignition: Run a 20 gauge red wire from the ignition pin on the key switch to near the EHC. Connect this red ignition wire with:
- Red wire; 2004 EHC position 13 (coil power).
- Red wire; 2004 EHC position 14 (ignition module power.)
- Red wire; 2004 EHC position 29 (speed sensor power).
- Red wire; 2004 EHC position 50 (speedometer power).
- Red wire; 2004 EHC position 32 (annunciator/tach power).
- One new 20 gauge red wire for 10A brake relay power.
- One new 20 gauge red wire for 10A start relay power.
Starting system:
- connect the new 10A start wire to the common pin of the 10A start relay.
- Add a jumper wire from that pin, to one of the coil pins of the 10A start relay.
- To other coil pin of the 10A start relay, connect green wire at 2004 EHC position 8 (starter button).
- Connect normally open pin on 10A start relay, to one coil pin on the 40A start relay.
- Connect other coil pin on 40A start relay to ground.
- Connect common pin of 40A relay to battery with a new 40A fuse holder.
- Connect normally open pin of 40A relay to Green wire, attached to 2004 EHC, going to starter solenoid (On the 2004 the green starter solenoid wire comes directly out of the EHC).
- Also connect yellow wire, from compression releases, to normally open pin on 40A relay (On the 2004 the yellow compression release wire comes directly out of the EHC).
Tachometer: combine the following tachometer wires:
- Green wire; 2004 EHC position 20 (tach signal from ignition module).
- Yellow wire; 2004 EHC position 21 (to tachometer).
You should now be able to reconnect the battery, turn the key to first position and start it up (if there’s gas in the carb), but no brake lights yet. Oil light and tach should work now.
Brake lights:
- connect the new 10A brake wire to the common pin of the 10A brake relay.
- Add a jumper wire from that pin, to one of the coil pins of the 10A brake relay.
- To the other coil pin of the 10A brake relay connect both:
- Orange wire; 2004 EHC position 4 (front brake switch).
- Orange wire; 2004 EHC position 23 (rear brake switch).
- Connect normally open pin on 10A brake relay, to one coil pin on the 30A brake relay.
- Connect other coil pin on 30A brake relay to ground.
- Connect common pin of 30A brake relay to battery with a new 20A fuse holder.
- Connect normally open pin of 30A brake relay to:
a. brown wire at 2004 EHC position 12 (right rear directional).
b. violet wire at 2004 EHC position 11 (left rear directional).
You should now be ready to ride……at least in the daytime, remember to use your hand signals.
Lights: If you want low beam headlight and running lights, run another wire from the lights pin on the key switch to near the EHC, and combine with:
- Yellow wire; 2004 EHC position 17 (low beam headlight).
- Red wire; 2004 EHC position 27 (left rear turn taillight).
- Red wire; 2004 EHC position 28 (right rear turn taillight).
- Red wire; 2004 EHC position 49 (tag light).
- Red wire; 2004 EHC position 30 (left front turn marker).
- Red wire; 2004 EHC position 31 (right front turn marker).
The following wires are not used in the wire plus WP374 installation for a 2004 Dog:
- White wire; 2004 EHC position 34 (neutral)
- Orange wire; 2004 EHC position 18 (input from old ignition switch)
- Black wire at 2004 EHC position #38 (ignition switch ground).
You should now be ready to ride……day or night, and again, remember to use your hand signals.
HINT: crank your Dog in position 1 on the key switch, then after its running turn to position 2 so the lights come on for safety.
See the attached PDFs.
Hope this helps someone.
Guess I should use the time to clean it up. Thanks for letting me vent :up:
