CUSTOM WIRE HARNESS 150cc GY6 SWAPPED SCOOTER

Introduction

In this tutorial, we will guide you through the process of creating a custom wire harness for a 150cc GY6 swapped scooter. Whether you're looking to simplify your wiring or add functionality like switches for headlights and underglow lighting, this step-by-step guide will provide you with the essential information to complete your project successfully.

Step 1: Gather Your Materials

Before starting the wiring process, ensure you have all necessary materials at hand. This will make the task smoother and more efficient.

• Wire harness kit (including various wire gauges)
• Connectors and terminals
• Heat shrink tubing
• Electrical tape
• Wire loom or protective wrap
• Switches for headlights, taillights, and underglow
• Wire stripper and crimping tool
• Multimeter for testing connections

Step 2: Understand the Basic Wiring Requirements

Familiarize yourself with the minimal wiring needed for a stripped-down scooter setup. This typically includes:

• Power supply wires (positive and negative)
• Wires for lights (headlight, taillight)
• Ground wires
• Wires for any additional features (e.g., underglow)

Practical Tip

Refer to a wiring diagram specific to the GY6 engine to understand where each wire connects. This ensures you won't miss any critical connections.

Step 3: Strip and Prepare Your Wires

Prepare your wires for connection by stripping the ends to expose copper.

• Use a wire stripper to remove about 1/4 inch of insulation.
• Ensure you have enough length for each connection but avoid excessive slack.

Step 4: Connect Your Wires

Start making the necessary connections according to your wiring plan:

• Headlight Connection

  • Connect the headlight wire to the power supply.
  • Use a switch to control the headlight.

• Taillight Connection

  • Connect the taillight wire similarly with a dedicated switch.

• Underglow Connection

  • Connect the underglow wires to a switch for easy activation.

Common Pitfall

Ensure that you connect the positive and negative wires correctly to avoid short circuits. Double-check your connections with a multimeter.

Step 5: Test Your Connections

Before finalizing the installation, it's crucial to test your wiring:

• Turn on each switch to verify that the corresponding lights and features work.
• Use a multimeter to check for continuity and proper voltage.

Step 6: Secure and Protect Your Harness

Once everything is functioning correctly, it's time to secure your wiring:

• Use heat shrink tubing over each connection for insulation.
• Wrap the entire harness with electrical tape or use a wire loom to protect against wear and tear.

Step 7: Final Assembly

With everything secured and tested:

• Tuck the wire harness neatly under the scooter's body.
• Ensure that no wires are exposed or at risk of getting caught in any moving parts.

Conclusion

Creating a custom wire harness for your 150cc GY6 swapped scooter can enhance both functionality and aesthetics. By following these steps, you can ensure a clean, safe, and efficient wiring setup. Once completed, consider adding additional features like LED indicators or a more advanced lighting system to further customize your ride. Enjoy your newly wired scooter!