Running without bulky wiring harness?

drafter89

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Have this 81 xs650, electronic ignition, it didnt come with the wiring harness and I was wondering if I can run it without the huge mess of a harness. All I want to run is a headlight,tailight...no horn, speedo tach, none of that stuff. What all (electrical) components would I need to get this thing running. I have a battery and the coil/plugs and plug wires. Thanks
 
http://www.xs650.com/forum/showthread.php?t=61

This is the diagram I used to make my own harness and cut out redundancies. Use this paired with your manual ( for wire colors) it will be up to you where to place certain things, like ignition and fuse panel along the circuit. Study it, use the simplified version to decide what you need and the manual version (I'm assuming your '81 is a SH, same as mine) to determine wire colors and which redundancies to remove etc.
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Make sure you are running heavy enough wire where it needs it. A little searching through that thread and you should find everything you need to know! Good luck! Took me a couple weeks to get it all running again, but if I can do it, anyone can!
 
I think im going to buy that chopper harness off mikexs or whatever because thats what I am trying to build. Wonder if that would be easier than buying a bunch of wire and starting from scratch??
 
The chopper harness you're wanting is from TC Bros, just make sure you buy the right one. Correct pin # coming outta the stator....
 
Mikes might sell it to, not sure. What I mean is get the connector to match up to your TCI box, the right # of pins to marry to your TCI...
 
Its real simple to make up a chopper harness

3 wires for head light HIGH/LOW/GROUND
3 wires for tail light BRAKE/RUNNING light/GROUND
2 wires for horn GROUND/12 volts from switch
2 wire for rear brake switch 12 volts to switch/WIRE TO TAIL LIGHT
2 wires for coil and ignition TWO 12 volts wires
Four position fuse box
TIE ALL THE GROUNDS TOGETHER
ON/OFF switch -LIGHT switch for h/l
Horn Button
 
Its real simple to make up a chopper harness

3 wires for head light HIGH/LOW/GROUND
3 wires for tail light BRAKE/RUNNING light/GROUND
2 wires for horn GROUND/12 volts from switch
2 wire for rear brake switch 12 volts to switch/WIRE TO TAIL LIGHT
2 wires for coil and ignition TWO 12 volts wires
Four position fuse box
TIE ALL THE GROUNDS TOGETHER
ON/OFF switch -LIGHT switch for h/l
Horn Button

You are the man Daddy G!:thumbsup: Thanks a ton!
 
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