Wiring updates.

[Viktory2k1]

Greetings!
Today I installed the missing engine coupler. After studying the wiring diagram, I found a few problems. First, I thing the stator wires are suppose to connect through the back side of connector. I have them in front which seems to may wires tight and against flywheel housing bolt, right where I put more butt connectors(at least there shrinkable). A few hours of running and I can see rubbed through wires so maybe I should reroute them.
2nd thing is someone seemingly hardwired the ign switch wire for reasons unknown. Mine is a white wire going directly to cdi box black wire. I put speaker terminals on them for now but I know where they are suppose to go. White comes off ign switch and goes in harness(if these pics are any good, you can see a tiny white wire sticking out of the ends) down to terminal block and from there goes under jackshaft to engine coupler. Other side of plug goes to black to cdi box connector style B. I would have done this but missing a few terminals for connectors. I have to find oe style terminal crimp connectors for these. I have most wiring in place but lacking terminals that fit in plugs. Tried some I have on hand but don't fit.
I have one more pic to post and will post it on a reply to this. If you notice airbox hose is missing, wait till pic of inside of hood.

[Viktory2k1]

This is a pic of inside of hood of where air intake shroud should be behind headlight. I have no idea what someone tried to do here.

[harleysportster]

Greetings!
Today I installed the missing engine coupler. After studying the wiring diagram, I found a few problems. First, I thing the stator wires are suppose to connect through the back side of connector. I have them in front which seems to may wires tight and against flywheel housing bolt, right where I put more butt connectors(at least there shrinkable). A few hours of running and I can see rubbed through wires so maybe I should reroute them.
2nd thing is someone seemingly hardwired the ign switch wire for reasons unknown. Mine is a white wire going directly to cdi box black wire. I put speaker terminals on them for now but I know where they are suppose to go. White comes off ign switch and goes in harness(if these pics are any good, you can see a tiny white wire sticking out of the ends) down to terminal block and from there goes under jackshaft to engine coupler. Other side of plug goes to black to cdi box connector style B. I would have done this but missing a few terminals for connectors. I have to find oe style terminal crimp connectors for these. I have most wiring in place but lacking terminals that fit in plugs. Tried some I have on hand but don't fit.
I have one more pic to post and will post it on a reply to this. If you notice airbox hose is missing, wait till pic of inside of hood.

Vic,
You did good installing the engine connector, since it was missing and you had no idea where it was. The lighting coil spades go in the connector from the same direction as the black ground wire that came with it. You have it wired correctly but it would be better to reroute the wires to the inner side, towards the exhuast, which means you will need to remove the spades from the connector and come in from other side of the steel bracket. What you found with the white wire to the CDI box is actually normal, I'll explain.
Originally, the white wire ignition circuit was included in the wire harness down to the terminal block and was included with the wire harness to the engine connector. From there, the black wire from the CDI was plugged into the engine connector, matting up to it. This was standard for the '76 Cyclone/Liquifire snowmobiles. During that model year, it was discovered that if the engine connector came loose and seperated while snowmobiling, there is no way of turning off the engine in an emergency. John Deere had a safety improvement program that when a sled came back to the dealer for repair, the white wire was cut from the harness and connected directly to the cdi. This was carried over into the production of the 77/78 models at the factory.
Did you install the short wire harness that I sent you? You will notice that white wire was cut back on that. Looking at your pictures, I see the white wire cut or removed at all the junction areas.

[TASKY]

I remember scratching my head over that white wire. As usual excellent explanation Harley.

[harleysportster]

1976 wiring

1977/78 wiring, note the change of the white wire removed from the main terminal board

[Viktory2k1]

Without going outside and looking at the connector, I do not remember seeing a white wire fragment on connector. So dealer did this?
It does unplug sort of easy. My plan is to connect the black cdi wire to the lower left terminal on fan side(viewed from on seat).
White wire will go from key to harness to junction block to other side of plug(lower left). Fan side will be from to left to right and down to left : gr gr open black black black. unplugable side will be as sitting on seat: gr gr open black white black. Center terminal closest to engine will be left empty for mounting bolt. Or maybe I should leave it like it is except rerouting the stator wires to motor side. I can see that plug popping out at the wrong moment. I still want a kill switch on handlebar next to throttle lever. Going to look now on ebay.
The wiring harness you sent is routed in the white sleeve thing. It sucked to get it all through but ok now. The hardest part was that ground terminal that goes to back side of voltage reg. I think a trained rat could do it with no problem. Very limited access unless you remove fuel tank.
I did not touch sled tonight though, I had a million brakelines to replace on a 99 sonata. Now thats good but fuel line leaking too and front right wheel bearing. All tools wet due to dewpoint and temp. I had to soak in water and brake fluid for 3 hours on the floor and now gas. yeay. Only thing I do to earn money these days.
3 to 5" snow Wednesday here so its all sled. But that car is in garage. hmmmmm. We'll see.
we hit 60F today...
Later
vic

[harleysportster]

Vic,
You can wire it back as original. One thing I would do is wrap a small wire-tie around the engine connector, locking it together. That way it can't pop apart. You mentioned that you were using speaker connectors, that's fine, just tape them up well so it doesn't short out.

[Viktory2k1]

Didnt get a chance to work on sled today. Looked at belt and talked with harley. I think engagement rpm is too low and belt is suspect or motor position as it is very hard to remove. Belt is Carlisle max1078M2. Otherwise a new clutch spring is in order.
Everything is frozen at this time after the 2 inches of rain and falling temps. We did get maybe 2 inches of snow today but temp in mid teens now and very windy. I will check real rpms soon with my meter if it has that function. Pics of it will follow. will have to read manual again.
Still have to reroute stator wires to motor side of engine connector. Still watching emergency stop buttons on ebay or try to repair it.
going to check in to low engagement rpm now.

[Viktory2k1]

http://www.readbag.com/cptbelts-pdf-cat ... -snowbelts
according to this site, I do have the correct belt for 76 and 78 cyclones. 77 has to be the same.

[harleysportster]

http://www.readbag.com/cptbelts-pdf-cat ... -snowbelts
according to this site, I do have the correct belt for 76 and 78 cyclones. 77 has to be the same.

Vic,
I gave you bad info last night, yes you do have the correct belt. Check this out.
http://www.green-sleds.com/community/vi ... b3#p105638