====== Honda NTV650 Revere - Wiring diagram ======

Here it is the **wiring diagram drawn in color**. It was derived by me from a black and white printed diagram from Honda. Inspecting the original drawing I spotted two erros: there were two missing joints. Both were in the main harness, one on the green wires and the other in the white/green wires.

{{.:honda_ntv650:honda-ntv650-revere-wiring-diagram.png?direct&600|Honda NTV650 Revere wiring diagram}}

Here it is the the PDF version: **{{.:honda_ntv650:honda-ntv650-revere-wiring-diagram.pdf|Honda NTV650 Revere wiring diagram (PDF)}}**.

===== Headlight wiring =====

{{.:honda_ntv650:honda-ntv650-wiring-headlight.png?320|NT650 Revere - Headlight}}
{{.:honda_ntv650:honda-ntv650-wiring-headlight.jpg?320|NT650 Revere - Headlight}}

===== Harness wires gauge =====

Inside the main wiring harness you will find at least three types of cables; they are stranded cables of different gauges, these are the specifications:

^  ^ Outer diameter  ^ Number of strands  ^ Strand diameter  ^ Cross-sectional area  ^ AWG equivalent  ^ Ampacity  ^ Load  ^
^ Thin    |  1.70 mm |  20 |  0.16 mm |  0.40 mm² | 21 AWG 20/34  |   2.9 A |   35 W |
^ Medium  |  1.85 mm |  30 |  0.16 mm |  0.60 mm² | 19 AWG 30/34  |   4.3 A |   52 W |
^ Thick   |  2.65 mm |  37 |  0.25 mm |  1.82 mm² | 15 AWG 37/30  |  13.0 A |  156 W |

The outer diameter refers to the overall cable, including the insulator. The AWG gauge is calculated measuring the diameter of the single strand and calculating the overall cross-sectional area; then the nearest value is looked into the [[wp>American_wire_gauge|AWG gauge table]].

**NOTICE**: The **19 AWG 30/34** notation means that there are 30 strands, each strand is an AWG #34 wire (0.160 mm diameter), the overall cross-sectional area is 0.60 mm², wich is almost an AWG #19 wire.

**NOTICE**: The **ampacity** reported in the table is the maximum electrical current in amperes that the conductor can carry for **2 meters**, mantaining the **voltage drop below 2%**. The formulas for calculating the voltage drop for a copper conductor (coefficient ρ = 1.68*10^-8 Ωm) are:

  * cable resistance **Ω** = (1,68 * 10^-8 **Ωm**) * (cable lenght **m**) / (cross sectional **m²**)
  * voltage drop **v** = (current **A**) * (cable resistance **Ω**)

==== Web References ====

  * **[[https://www.12voltplanet.co.uk/cable-sizing-selection.html?srsltid=AfmBOoptInzPqpV0xFYnLUYFca2adSF8JNfqOuBPz5iGTt-0YLcToALN|Cable Sizing & Selection]]**
  * **[[https://www.wirebarn.com/Wire-Size-Calculator-_ep_41.html|Wire Size Calculator]]**

===== Insulating tape =====

The main **wiring harness** is assembled using extensive **electrical tape**, both for the external wrapping and to insulate some internal connections. These are the characteristics of the tapes used:

{{ .:honda_ntv650:honda-electrical-tape.jpg?320|Electrical tapes used by Honda}}
^  Color  ^  Width  ^  Thickness  ^
| Black   |  20 mm  |  0.10 mm |
| Blue    |  40 mm  |  0.20 mm |

The black tape is very soft and flexible, unlike the ones commonly found on the market which have a thickness of 0.13 or even more.

===== Connectors =====

The **mini connectors** used into the wiring harness are the **MTW Sumitomo** unsealed series, with **2.8 mm** terminals. Here are the part numbers:

^  Sumitomo MTW series  ^^
^ 6040-2111  | Housing Female, 2P  |
^ 6030-2981  | Housing Male, 2P    |
^ 6040-3111  | Housing Female, 3P  |
^ 6030-3991  | Housing Male, 3P    |
^ 6040-4111  | Housing Female, 4P  |
^ 6030-4991  | Housing Male, 4P    |
^ 6040-9111  | Housing Female, 9P  |
^ 6030-9991  | Housing Male, 9P    |
^ 1500-0071  | Male terminal 2.8 mm, tinned brass  |
^ 1800-2097  | Male terminal 2.8 mm, nickel-plated copper  |
^ 8240-4092  | Female terminal 2.8 mm, tinned brass  |
^ 8240-4050  | Female terminal 2.8 mm, nickel-plated copper  |

Here you can download the **{{.:honda_ntv650:sumitomo-mtw-connectors.pdf|Sumitomo MTW series conntector catalog}}**. Beware of the **thickness** of the male terminal: it original is **0.5 mm**, whereas you can find many low quality replicas that are only 0.3 mm.



===== Fuel pump connector polarity =====

After disassembling the carburetors you may want to force the fuel to fill them again. Using the start button and letting the entire engine rawwing for a long time may be an high load for the battery, so you may prefer to provide 12 V directly to the pump connector.

In this photo you see the polarity (red is positive and black is negative) of the connector from the wiring harness to the pump:

{{.:honda_ntv650:ntv650-fuel-pump-connector-polarity.jpg?nolink&320|NT650 Revere - Fuel pump connector}}

You will hear the noise from the working pump. Ance the carburetors are full, the pump will stop.

===== Connectors wires color =====

{{.:honda_ntv650:ntv650-revere-connector-9p-mini-red.png?direct&360|NTV 650 Revere 9P Mini Red Connector}}
{{.:honda_ntv650:ntv650-revere-connector-9p-mini-white.png?direct&360|NTV 650 Revere 9P Mini White Connector}}

{{.:honda_ntv650:ntv650-revere-fuse-box.png?direct&360|NTV 650 Revere Fuses Box}}