wiring harness

7

77-650

XS650 Member
Messages
22
Reaction score
0
Points
1
Location
Nw pa
So since I bought this bike I've had nothing but trouble with wiring someone has messed with it pretty bad and now I have a short some where in my turn signals I think its just one thing after an other I was wondering how hard it is too just put a new wiring harness in it

Posted via Mobile
 
If you are not familiar with your wiring you can make a diagram of what you have got, or, tear it out and start again knowing what everything does and how it is connected.

It's fun learning.

Anlaf
 

Attachments

  • image.jpg
    image.jpg
    5.6 KB · Views: 242
Im just thinking about buying a new one bc mine is so cobbled up and it just keeps giving me problems

Posted via Mobile
 
I believe some harnesses are available, but I cannot comment on them, I have had so much fun making my own and learning as I go, with some great help on tap all the way.

Anlaf
 
Im just thinking about buying a new one bc mine is so cobbled up and it just keeps giving me problems

Posted via Mobile
 
Ok I just don't rly have much experience when it comes to wiring im not real comfortable with wiring myself
 
If you try building your own, you will find it's not as hard as you think. Just take it one system at a time.
Start with the charging system, then add your ignition. Once you get it to run and charge right adding other things like the head and tail lights, horn, turns, e-start, any other goodies you might want, will be easy. Just add a fuse, run the wire, any switches, the items and good grounds.
Don't be afraid. As long as you don't alter the stock plugs on the items you use you can always give up on your own and get a new one.
The new one will work but building your own is a very good learning experience. Youir confidence lewvel of your skills will greatly improve.
Also if you bild your own you will better understand how things work. This will make trouble shooting problems much simplier.
One thing I will suggest is to use wires the same colors as stock. This helps when trouble shooting. We on here think in stock colors.
Leo
 
I'm with XSLeo all the way. I started from scratch, and I did just as XSLeo describes, and now I feel confident and know what goes where, and what it does.

Anlaf
 
Ok well what do u do when it comes to wiring in the relays and all that

Posted via Mobile
 
Anlaf and XSLeo, I'm running into the same issue with my harness being all jacked up. Someone actually tried to use speaker wire to run an anti theft or something to that little black box. I'm willing to give it a shot building my own, however did you just pull your own and try to replicate it or was there another diagram to help you? I'm not sure which wires are real and which aren't.
SPqjdjGLuy-IMG_0519.JPG
 
I am using a mikesxs repop harness on the XS1 without problem. Since this was a resto project, I wanted an OE similar electrical system. However, I feel that the wires and connectors seem to be a little undersized. That being said, when this bike went into storage 40 years ago I had rewired it quite simply, theres not really much there, sort thru the wiring diagram and only use what you need. Mikesxs does have the needed connectors and I' sure that there are also other suppliers if mikexs isn't a favored supplier.
 
I guess I have a different opinion about this. I'd rather start with the original harness, follow a good diagram, inspect and clean every connection (gotta do it anyways), solder in wires and connectors where needed. This gives me the whole picture of what was not right and the wire colors mostly still match the stock diagram for future work needed. I have no problem unwrapping and rewrapping with un-sticky and sticky electrical tape, small zip ties over the sticky tape ends. I'm doing a bobber right now, starting with the stock harness, I'll remove the unwanted functions and fabricate everything to the right lengths.

I've never had a harness that beat me yet.

Scott
 
I agree with Scott. Your harness looks mostly intact with just a few added "extras". With a good cleaning and a few repairs, I think you'll be fine. For cleaning, I've been using a product called the Tannery for many years. It's a spray on leather, vinyl, rubber, and plastic cleaner. Easy to use and does a wonderful job .....

http://www.acehardware.com/product/index.jsp?productId=31784526

Rather than spend for a new harness, I would recommend putting that money towards a good crimper and terminal kit. I got a couple from these guys and can now make repairs pretty much as good as factory .....

http://vintageconnections.com/
 
Last edited:
Shoddy wiring "fixes" are all too common on old bikes, even new ones. People who don't have a clue shouldn't mess with this stuff but they do anyway, lol. Years ago, me and a buddy were riding with a guy on a Harley. The Harley quit. A quick examination revealed a broken wire. He had replaced a wire down around the battery and his "fix" broke. It broke because he used a strand of common solid core house wire, lol.
 
I agree that the harness you have could be fixed up and if connectors need to be replaced they are easy to get. If you own a motorcycle there is a time where you need to sit down and learn your bike so if you do break down you can get it back running. Some of the harnesses from MIKES have different colors and connectors are different but they do work.. If its a stock bike KEEP it stock with a stock harness if its a chop or brat then you can change the harness to what you want. If you get stuck you can contact me at DADDYGCYCLES@YAHOO.COM and I will give you my number and I also have facetime on my phone so I can see what you are doing if you have it also.. JUMP IN YOU CAN DO IT
 
Cool, I appreciate the input from everyone and know that I will likely have more questions in the future. Time to start digging in and tearing it apart. The main thing would be to mark where everything goes probably, so I don't end up with any loose ends. Haha
 
learn to continuity test the loom and replace and clean the connectors, (that need to be), as you go. That way you will find out if any wires are broken in the loom, just changing connectors without testing is a wast of time and money.

Here are some electrical links. I think these are the best ones for a start, and cover a lot of bases.
http://www.xs650.com/threads/wiring-harness-musings.18925/
http://www.xs650.com/threads/grounds-so-important.41775/
http://www.xs650.com/threads/what-happens-when-you-turn-your-key-on.9625/
http://www.xs650.com/threads/expanded-charging-system-guide-in-progress.10561/
 
Last edited:

Similar threads

T
Wiring question for horn
Replies
1
Views
262
sleddog83
sleddog83
C
‘77 front turn signal help
2
Replies
29
Views
817
Wingedwheel
Wingedwheel
oberling
Need advice for complete rewire of bike
Replies
6
Views
936
XSLeo
XSLeo
T
Blinker wiring
Replies
16
Views
711
jpdevol
jpdevol
C
Wiring Overhaul
Replies
2
Views
366
jpdevol
jpdevol
Back
Top