Could use a lil' help with replacing old damaged harness with a Chinese Wire Harness. The Harness I got is this one.
Seller claimed on page 3 of answers that it would fit a Bayou 220. Well the stator would not fit the housing mount and need help wiring in the old exhisting stator into the new harness any help would be appreciated...

 

Hey Bobby ive got a question for you on starting with a new harness. Whats the purpose of replacing the harness vs rewiring the harness? I have 2 of these bikes and i went through with my multimeter some crimps and heat shrink and the bike works great without replacing the harness. Im only bringing this up because a lot of folks on here will say you should keep the harness the same.

In the end ill say you do you, but if you can keep oem you will increase your options for repair and replacement.

 

While it is possible to fit a wiring harness made for a totally different bike, it is far harder than fixing the existing one, unless it has been on fire or hacked to pieces by an idiot. The thick red wire is not thick enough to carry the current required to spin a 220cc engine over so you need the old one to solenoid and starter. Kawasaki use black/yellow for earth wires and white for the pos from battery to rectifier and ignition switch. Seven wire CDI on Kawasaki, looks like the pulse coil is two wire, ie, not earthed, black and blue wires? Power coil similar, red and black/red? Kill wire to ign switch is yellow/red and wire to coil green/white. Two stator wires to regulator, not sure if this means single phase or if the earth is used as a third phase, rectifier would have to be for the same type, whichever that is.

 

Hi. Thanks for replying. I also just aquired 2 of the Kawasaki Batou 220's. 1 has no harness and the other one is completelty hacked up. I have pdf service manual I downloaded for like $9.00 I think I paid for it so I could have the wire diagrams. Original wire harnesses are crazy priced on ebay for used harnesses so I elected to buy the Chinese harness hoping someone had already decoded the wires to make installation a little easier, but also so I would have the wires if I had to take the harness apart and wire everything from scratch from the diagrams.
I only paid $100 for both 220's and got the 1 to turn over and start with the old hacked up harness which had things bypassed. So ordered the Cheap harness along with a new Carbuerator, air filter, fuel, oil filters and choke cable that was missing. Thinking I have the Stator wires mapped out for the new harness, Because the hole of the Stator with the cheap harness is slightly smaller than the hub even though the Seller stated it would fit the 220 & 250 Bayous Which worked out in the end because they sent me another replacement harness and told me to keep or discard the 1st harness. So now I have another harness for the other 220 which was missing the harness. So a 2 for 1 deal is great in my book even if I have to take them apart and wire up from scratch from the diagrams and just relabel the different color wires to build the new harnesses. Also when I complained about the 2nd Stator in the replacement harness not fitting and asked them just to send me a Stator that actually fits thew screwed up and sent me a 2nd Carbuerator and refunded my money. So now I have a harness and new Carbuerator for both 220's... So not complaining a bit about that. lol...

 

Hi merryman. Thanks for replying. Yes I have the larger Battery to solenoid and solenoind to starter cables. Previous or previous owners hacked up the original wire harness horribly. Looks like they bypassed a few things hooking up minium wires.
Seen some of your replies on Billy Hilly's Post in 2019 on this same subject of using a Chinese wire harness on a 220. Hetting ready to reread it again to make heads and tails of this mess. I have a pdf service manual with the wire diagrams. In your opinion and experince can I use this harness or should I take the Chinese harness apart and use the wires to build a harness from scratch of the diagram below?
Any help on this to get these 2 machines up and running would be greatly appreciated...

 

To be honest, either hacking the new harness to pieces and using it to copy the original, or using the new one as is, with a few tweaks, are both fraught with difficulties. For a start, I would make a diagram of the new harness, the Kawasaki one is about as simple as you get, apart from the extra wires from stator to CDI, so the new harness may not be all that different. If it is similar, apart from colours, using it as is, and fitting the extra stator wires may be the way to go. Unless they are missing, I would use the existing CDI and regulator, as I wrote above, the Kawasaki stator may be three, or single, phase and the regulator needs to match. Also those non earthed power and pulse coils are better suited to a similar CDI. Though I expect you could earth the "return" wires and use a standard Chinese CDI if needs must.

 

Think I may have a configuration for wiring the original Stator to the Chinese Harness. Going to try and hook it up here in a few to see if it works.

Original stator to Chinese harness to Chinese regulator:

yellow - yellow - to white - to pink on Rectifier


pickup coil; - Blue - Black
capacitor charging coil; - Red - Red / Black
The black and the red/black of the original stator joined together to the green of the Chinese harness to the green of the Chinese CDI. This would make the 6 original Kawasaki = 5 of the Chinese harness.

Will post again later on with the outcome.

 

Well I hooked everything up. Wired up everything outside the frame so everything was easy to get at. Configuration seemed right. I had spark. Checked it 3 times. So I shrinked wrapped my connections, put all the wires back inside the frame and zip tied to the frame all nice and neat again. Put gas in the tank. Then it wouldn't start. Pulled the plug, no spark, put another plug in it to check still no spark. But had spark while wires were hanging outside the frame. So Tomorrow I'll have to go through the wires and try to figure out what's going on.
But the wire configuration was correct and had spark. That was most the battle, configuring everything to the Chinese Harness. So tomorrow I'll have to go through the wires and see if something got knocked loose putting them back inside the frame and installing the tank. Will post back again after that.