860 GT Headlamp Wiring Help Needed - Ducati.ms

confusa · Jul 5th, 2011, 11:47 pm

My 75 860 GT has a number of wiring modifications in the headlamp that previous owners did when they installed an air horn. Air horn is long gone and I am trying to track down some electrical gremlins so putting it back as close to stock as possible. It doesn't fit with any of the wiring diagrams I have seen. If someone with an 860 could pop off their headlight and let me know what wire color connects to what terminal I would be greatly indebted. Primarily I need to know what colors and the routing for the horn relay, flasher relay, and stop device. Signal flasher is fine I know. MANY bonus points for photos!

wdietz186 · Jul 6th, 2011, 9:05 am

IIRC the wiring diagram is available online at Bevelheaven in the manuals section.The wiring harness on the 860 is sort of inadequate to handle a modern light and the wire gauge is too small.The switches are crap too.
Unless you are doing a Resto you would probably be better off using modern switches and making a new harness.Incorporate a better fusebox too.

confusa · Jul 6th, 2011, 11:33 am

Quote:

Originally Posted by wdietz186

IIRC the wiring diagram is available online at Bevelheaven in the manuals section.The wiring harness on the 860 is sort of inadequate to handle a modern light and the wire gauge is too small.The switches are crap too.
Unless you are doing a Resto you would probably be better off using modern switches and making a new harness.Incorporate a better fusebox too.

I got the one off BevelHeaven, but it doesn't match my wiring at all. Also the one in the Clymer is off too.. If the one in the workshop manual for a US 860 is correct, then my wiring is very out of whack. Got jumped wires from the horn relay, over to the stop relay, over to the flasher relay that do not appear in either manual so I am not sure what the previous owner was doing.

confusa · Jul 9th, 2011, 6:59 pm

Enclosing some pictures of the mess in hopes someone can make sense of it. So many non standard things going on I can't make sense of it.

Flasher relay:

Stop relay:

Horn relay:

Duccout · Jul 10th, 2011, 12:42 am

The 860 models had a lot of trouble with the headlamp relay, and there were mods from Ducati to sort it out. Your bike looks like someone has been carrying out the work, so it may be OK.

wdietz186 · Jul 10th, 2011, 9:16 pm

Yup! It has been "re interpreted".All those un insulated connectors and exposed wire on the circuit boards are just asking to be shorted when the light is in the shell.As I said before it might be better to start over and make a new harness and use modern automotive relays and fusebox. I think there was a sort of universal harness plan on Bev Hev that you could make.

quidpro · Aug 2nd, 2011, 11:12 pm

I just noticed your post so I don't know if your problem is solved. I have the best wiring diagram for the 860 that i can send you and can also take some pics inside the headlamp but it's a rat's nest in there right from the start.

Lemme know if I can help. Off list at masslaw@gmail.com