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Ultima Plus Wiring Kit

Discussion in 'The Garage' started by Ozboy, Dec 5, 2019.

  1. Ozboy

    Ozboy XS650 Addict

    Hey Team
    I have been given a Ultima Plus kit from a friend who I helped rewire his caravan. He no longer needs it as he will go the mUnit path when he is ready (more work for me).
    I know I can build a new complete harness but you cant beat free and kinda hassle free plus I am a tight ass!!
    Currently away offshore on night shift and doing not a hell of a lot so I started planning this out. Most of it is sorted out but as it is for HD's the Japanese earth switching needs to be sorted so have a few questions.
    • Can the start button be wired to accept power in power out?
    • Has anyone had success using a change over relay as a safety start relay. I have seen the post on wiring them but does it work.
    If anyone can think of something else would be a great help.
  2. 5twins

    5twins XS650 Guru Top Contributor

    I don't think the horn or start button could be wired with power. They are "ground" buttons. When pressed, the wire attached to them is put to ground, into the button frame, then passing into the switch housing, into the bars, finally picked up by the black ground wire in the left switch and grounded to the harness in the headlight. So, horn power would need to be run to the horn, not the horn button. Starter power would need to go to the solenoid, or if you're retaining the starter cut-out safety relay, to that first. The relay will pass it on to the solenoid and also protect against starter engagement once the motor is running.
    Ozboy likes this.
  3. Ozboy

    Ozboy XS650 Addict

    Thanks 5t it was exactly what I thought. My next plan would be to use the Aux line to the safety relay and run another wire to the solenoid earth side from start button. As for the horn I guess the same. I have no plans for the Aux. I do have a spare pair of handle switch's I can take a look when back home.
  4. 5twins

    5twins XS650 Guru Top Contributor

    The solenoid earth side wire (blue/white) is what runs to the start button. When you press the start button, it grounds out and completes the starter circuit, activating the starter.
  5. Ozboy

    Ozboy XS650 Addict

    5t yep that's they only way it will work I am afraid with standard switches. Now if the earth form start side of harness was run I could do it but the kit is mostly chassis earth with power runs.
    I will run the coil and TCI power from the coil side of harness thru a 4 pin mini relay as the coils do consume power. I have this set up already.
  6. boonacka

    boonacka XS650 New Member

    Any updates with the Ultima 18-533 and its use on metric bikes? Id like to see what your final wiring diagram turned out to be or at least which wiring did you have to change from what the ultima diagram suggested. I'm a wiring newbie
  7. XSLeo

    XSLeo XS650 Guru Top Contributor

    As far as the starter relay is concerned it don't care if the button is before or after, so it can be wired with power from the button to the relay R/W wire and just ground the B/W wire or as stock with power to the relay and the button after to ground the circuit.
    On the horn you can do the same thing.As far as any other switches you will have to look at each thing the switch operates to determine if the power can flow either way.
    The big thing is that the circuit be complete. Power, thing to operate, and a switch, enough wire to reach everything, then back to ground. If you leave any off these things out it won't work.

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