Muckroot

XS650 Addict
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Hello all,

I've sketched up a wiring diagram for my 1975 XS650B, which is a hardtail chopper project.

it has the stock alternator, as well as:

a TCBro's reg/reg: http://www.tcbroschoppers.com/regulator-rectifier-yamaha-xs650-points-ignition-models.html.

a TCBro's headlight: http://www.tcbroschoppers.com/bates-style-headlight-5-784.html

a TCBro's ignition switch: https://www.mikesxs.net/yamaha-xs650-universal-ignition-switch-tc-bros-choppers.html

MikesXS condensers: https://www.mikesxs.net/yamaha-xs650-condenser-pack-all-650-s-with-points-oem-256-81625-10.html

MikesXS coils (I bought two): https://www.mikesxs.net/yamaha-xs650-oem-type-signal-output-ignition-coil-oem-254-82310-60-00.html

Also; new points, new plug wires, new plug caps, new (to me) advance unit, alternator brushes, and wiring.

I plan on getting :

a nice battery: http://www.tcbroschoppers.com/yuasa...tery-fits-yamaha-xs650-75-83-ytx14ahl-bs.html

the blinker relay : https://www.mikesxs.net/universal-dot-approved-round-oe-style-turn-signal-flasher-relay.html

Also, bar warmers, blinker lights, tail light/brake light, and other stuff not listed above.

I plan to get two terminal bars to connect the fuse array to the ignition switch. I am using a modified surplus ammo canister as the electrical box, so it'll be very water resistant, and for all intents and purposes as water tight as I can get it. all wires entering and exiting the box will have rubber grommets to ensure a snug fit, and to keep moisture out.
I plan to use these two terminal bars, one for everything powered in the "run" key position, and one for the headlight and tail light in the " lights" key position.
https://www.oreillyauto.com/detail/...-terminal-block/4721p5/2622494?q=4721p5&pos=0

https://www.oreillyauto.com/detail/...-terminal-block/4721p2/2622491?q=4721p2&pos=0

My questions are these :
Do I need to unground the alternator brushes?
does everything look O.K. with this diagram?
what amperages should the fuses lists be? (I'd like to use fuses suited for each component instead of a bunch of 20 amp ones.)
If I were to add a starter, how would I wire it?


IMG_20200704_235947.jpg

As I post this I am thoroughly exhausted, and have surely made a bunch of spelling mistakes. I'll review in the morning and make sure everything makes sense.


Best, Muckroot.
 
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What should I change so it is correct? I got the wiring for the stator, reg/rec, battery, and some of the ignition from this diagram:
noid-chopperwiringdiagram.jpg


Which talks about ungrounding the brushes. Do I need to wire the brushes differently when connecting them to the reg/rec if I want to not have to unground them? (that's my goal by the way, is to avoid having to buy nylon screws and futs around trying to unground the brushes)
 
In this other diagram, if we're only looking at the reg/rec, the key, the battery, and the alternator it is almost identical to what I have on my diagram. The only differences I can see are that I forgot to include a ground strap from the negative on the battery to the frame of the bike, and the F3 fuse in my diagram is after the positive wire splits to power the ignition switch. So the fuse only acts to protect the reg/rec, instead of also protecting the ignition switch.

*EDIT* in this diagram the stator has an extra wire, the brown wire for the second brush. in the diagram above this post there is no brown wire coming out of the alternator. Also, the regulator is just grounded to the frame, not directly to the battery.

Which design is correct? will the wiring of this diagram allow me to avoid ungrounding the brushes? should I unground the brushes anyway just to extend the life of the components, or do they have to be grounded with a design like this (this 1981 diagram)


*EDIT 2* I just checked, and my alternator has six wires coming out of it. three white, a yellow, a green, and a black. There is no brown wire on my alternator.

about-motorcycle-wiring-diagram-on-pinterest-buell-motorcycles.jpg
 
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Diagram in the link i provided...........Self explanatory............

Post up pics of your alternator and and associated wires that are connected from the old regulator and the rectifier. Wiring and connectors showing the wires in and out of the connectors..........

Using chopcult and other sites that are not XS650.com or thexscafe.com will often give the wrong information..............As is the case now and that diagram they post is laughable...........should be in the joke thread

.NOTE;
No, your stater shouldn't have a brown wire coming out of it

The diagram in post #4 is for the 80-83 bikes with Factory electronic ignition. 75 bikes have points..........Diagram is no relation to yours.....could be if your Stater has be swapped at some stage and possably a later model one was swapped in............This cannot be confirmed without photos
 
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Post up pics of your alternator and and associated wires that are connected from the old regulator and the rectifier. Wiring and connectors showing the wires in and out of the connectors..........

Excellent information, thank you. The bike did not come with any electrical components except the stator when I bought it, so everything I'm putting together is new stuff. I can tell you that the brush screws that were installed on the stator when I got it were metal. I will gladly take pictures as soon as I can, as well as redraw the wiring diagram I made for my bike to make sure I have everything right on paper.

Also, I'm using the info from your link the second go around, as it seems far more relevant to my setup than any of the diagrams I looked at previously
 
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