Zeeltronic wiring

S

Smith

Location
Washington
Hi, its my first time installing a zeeltronic and was hoping to get a little help and feedback with the wiring. I attached a picture of my wiring

I have supplied a fused power wire to the zeel but am not sure if all the wiring is correct, I have 3 leads that i don't see a connection for.

There is a grey wire off the Zeel with no connection that does not route through the zeel harness plug. Is this the switching wire between programs? Does it just need to connect to ground? Online Zeel shows in their wiring diagram that the grey wire is the signal counter wire? Is this old info? Doesn't the counter go through the prebuilt harness?

I also have a pink wire that splices for a male and female connection, both of these ends are not connected. Is this normal with the install? Can I just plug these into them selves just to close the wire ends?

There is a orange wire off the harness that runs to the flywheel area that is not connected? Is this correct I don't see any place for the connection20210116_141111.jpg

Any help would be greatly appreciated, thanks
 
S

Scarab195

Location
Ct
Pink is the switch between tunes, grounded or ungrounded. I dont recall having an extra grey in either of mine. I have an open zeel box I can look at in the morning

Sent from my SM-G960U using Tapatalk
 
S

Storbeck

Location
Minnesota
The pink wire on the harness side of the plug is used by the oem wire harness for the temp sensor, usually that is not used for aftermarket cdi, so zeeltronic connected the map switch wire to that spot on the oem plug so that you'd have a nice oem plug and wire to use for the map switch.

Grey on that model of cdi is for the tachometer out. You don't need to do anything with it if you're not using a tach.

I'm not sure what you mean about an orange wire. Usually orange is the positive wire to the ignition coil. It goes straight from the cdi plug to the ignition coil, which it is doing in the picture as far as I can see. I can't see any unaccounted for orange wires in your picture.

There will be two wires in the oem harness that go from the mag cover area to the plug for the cdi, usually brown and blue, that will not have any connection to the zeeltronic. Those are the "charge coils" in Yamaha terms, they charge the capacitor in the oem cdi (basically power the spark), Zeel doesn't use them because it uses battery voltage for that function.

There are also usually wires in the box that go to the gauge cluster in the couch that you don't need in a stand up. They usually go to an extra plug in the harness for the start/stop switch wires.

Usually the wires for the guage are:

1. a green wire (I can see it in your picture, it has a splice that goes between two connections in one of the green wires, you can just take that out and plug the two green plugs together. The green wire is raw unrectified and unregulated voltage from the charging system, it's used by the tachometer in the oem guage.

2. a pink wire, again this usually is a deal where it is a splice between two plugs, it's for the temp sensor which is unused in any zeeltronic application

3. red wire, powers the guage

4. black wire, ground.
 
S

Smith

Location
Washington
Thank you. I was wrong on my colors, the orange is direct to the coil and my pink was unused.

I wired my pink to ground with a splice in the middle to allow for switching

I wanted to double check with the green wires from the mag cover. There are two, both of these should be plugged directly into the 2 green leads on the regulator? And the green connections on the harness up to the switch should be left disconnected?

I have left the split pink and green wires from the switch side disconnected?20210120_165240.jpg
 
S

Storbeck

Location
Minnesota
Yes your green wires are connected correctly. The green wire going up the wire harness is only used by the gauge on the couch, which you are not using, so really you could completely get rid of it or just leave it there. Same story with the pink, the wire going up the harness is for the gauge on the couch and you are not using it.

As far as I can see you've got everything hooked up right.
 
S

Smith

Location
Washington
Will this still charge the battery? if the charge coils not being plugged in will allow for battery charging? Is that a whole different thing?
 
S

Storbeck

Location
Minnesota
The thing that is not plugged in is the thing that charges the capacitor in the CDI for the stock ignition, it's not the thing that charges the battery, it's only for spark. So the stock system has a coil in the magneto that is used for powering the spark, and a different coil that is used for charging the battery, they are separate. The Zeel is powered by the battery so it doesn't use that separate coil for powering the spark. Yamaha terminology is a little confusing the "charge coil" is not used for charging the battery it is used for charging the capacitor in the CDI.


What charges the battery are the two green wires going to the regulator/rectifier which produces the DC current to charge the battery via the red wire coming out of the regulator/rectifier.

So yes, this will charge the battery, assuming everything is hooked up right. Make sure that you can trace a path from the regulator rectifier to the battery through all of those red wire connections.

One note, I can't completely tell if the black thing in the power wire for the zeel is a fuse or just a connector, but it's a good idea to have a fuse there.
 
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