Wiring tips and pics

itschrisb · Sep 30, 2020

I apologize if this is already a thing. I know there are quite a few “wiring diagram” thread out there but one thing those threads usually lack is pictures of the physical wiring on the bike.

I’m in the process of rewiring two bikes right now and would love to see some pics and tips on making it cleaner. Connectors, routing, protective covers, switches, etc. Anything wiring related I’m interested in!

willis · Sep 30, 2020

Not sure if you saw THIS thread. I bought factory style bullet connectors from VintageConnections along with a quality crimp gun. I also used a lot of expandable sheathing with some self adhesive shrink wrap for the ends. Halfmile shows a good example in that thread I linked above. I also use zipties and small P clams to create a "standoffs" and cable routing guides. Most of all, take your time and lay everything out on the bike first to be sure you have everything you need before you close up your heat shrink.

SEd27 · Sep 30, 2020

willis said:
Not sure if you saw THIS thread. I bought factory style bullet connectors from VintageConnections along with a quality crimp gun. I also used a lot of expandable sheathing with some self adhesive shrink wrap for the ends. Halfmile shows a good example in that thread I linked above. I also use zipties and small P clams to create a "standoffs" and cable routing guides. Most of all, take your time and lay everything out on the bike first to be sure you have everything you need before you close up your heat shrink.

+1 on purchasing a ratcheting crimper. After a bit of practice you will consistently get factory looking crimps.

650Skull · Sep 30, 2020

A good thread unfortunately the OP hasn't been on here for 6 years and his pics are obsolete......... Can google the names if need be

http://www.xs650.com/threads/wiring-harness-musings.18925/

itschrisb · Oct 1, 2020

650Skull said:
A good thread unfortunately the OP hasn't been on here for 6 years and his pics are obsolete......... Can google the names if need be

http://www.xs650.com/threads/wiring-harness-musings.18925/

this is looking like an awesome thread! Thanks for that.

Out of curiosity how many people are typically running relays on their bikes? The PO has a relay for just about everything. I understand the benefits for running relays for the headlight but is it worth running a relay for the main power to say a fuse box?

member3480 · Oct 2, 2020

I will show you how to wire when you come pickup the air filters.
This is a basic design. I have made and sold now over 250 harness kits since 2000

5twins · Oct 2, 2020

Don't know where I found these, some on-line manual no doubt, but maybe they'll be of some help. They show factory wiring and cable routing .....

If you've installed lower bars, you may need to alter the clutch and throttle cable routing a little.

Wiring tips and pics

itschrisb

XS650 Addict

willis

xsive compulsive disorder

SEd27

XS650 Addict

650Skull

Cockytoo

itschrisb

XS650 Addict

member3480

RICH

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5twins

XS650 Guru

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