After doing some research, I have found that the stator wires (coming from the stator) are 12g wires. For the harness, I wanted to increase the gauge size for both the stator wires and the DC return wires (to minimize voltage drop), as the length is going to be approximately 10′ (for the XP4). One of our vendors, Hawk Engineering, apparently makes a relocation harness, so I asked him what gauge wire he uses on his stator harness, he responded "10 gauge". For the DC return wires, I chose to run 8g wire for the return back to the battery, as this VR is capable of supporting upwards of 40A.
So, here is what I’ve got:
The 3-wire stator plug is a Metripack 630 sealed terminal kit
This kit can be purchased at Cycle Terminal: Metri-Pack 280 – 630
Keep in mind, these connectors require a very pricey crimp tool for a "professional" installation. (Being more of a shadetree kind of mechanic, I am choosing to carefully crimp the terminals onto the wire, followed by a good soldering of each terminal. This has worked well in the past for me.) I will be running 10g wire for the stator wire portion of the harness.
Now for the DC return from under the hood, I plan on mounting a double 1/4" junction post. This way the OEM VR has a place to land the +/- wires without modification. This is the junction post I found on ebay:
7277025 Dual Post Mounting Kit 1 4 x 20 Red Black Posts with Boots | eBay
For the DC return from the above double junction post, I am running 8g wire back to a single 1/4" junction post located near the starter relay and from this junction post, I am inserting a 12g (or 3sq mm) fusible link between the new junction post and the battery terminal on the starter relay (the location where the original VR was landed). This fusible link will protect the 8g wire from a short circuit.
The ground return from under the hood, will go to the OEM ground lug terminal under the rear seat.
Junction Block Power Post 1 4" Red Positive | eBay
I am working on a couple different ways to get the VR mounted….we’ll see how that turns out……
Again, I’m no engineer and there may be other ways to go about this…..this is what I have arrived at to relocate my VR. I purchased the 8 and 10g wire locally, so my cost to make this complete harness will be in the neighborhood of $60.
Later, I will post up some pics of the installed components as I install them for easier reference.
If you have other Ideas that have worked or that can help other members….lets hear it!!
As always…..mod at your own risk!!!:ride:
