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Wire harness questions before I start

Posted: Tue Sep 09, 2014 2:05 pm
by Ruckenstein
Absolutely no experience with harnesses.

I'm in the process of slapping a dio into a ruckus and was wondering if the rectifier and Cdi distances were important to consider. I was wanting to locate as much as possible under the front box.
Will be using an old harness initially with a custom harness after I get me some education.

Re: Wire harness questions before I start

Posted: Tue Sep 09, 2014 4:06 pm
by LMH
Make sure to ground out the reg.

Re: Wire harness questions before I start

Posted: Tue Sep 09, 2014 4:41 pm
by Ruckenstein
Thanks a bunch! Any particular threads or websites come to mind for beginner DIY stuff like this?

Re: Wire harness questions before I start

Posted: Tue Sep 09, 2014 6:59 pm
by Johnniespeed
I have never done your exact swap, but have extensive harness swap experience.
First and foremost obtain a factory wire diagram for the correct year Dio engine you have. You will also need a factory diagram of the Ruckus harness layout.
Second make a sub- harness from scratch that exactly matches the Dio engine connections and mates to the Dio starter relay, Dio regulator/rectifier, cdi of the DIO, then mate that sub harness to the Ruckus harness.
I have transplanted many fuel injected engines into other non-matching vehicles and have had nothing but success with my methods. My charging systems, ignitions systems all work properly.