another first build thread.

[Chris_AWV_93]

so i just got my first XS650, its a 81 and it needs some bringing back to life. its got a TC bros hard tail, running engine, basically its a rolling chassis with an engine. im thinking i should start with knocking out electrical. im planning on starting fresh by tearing out all the old stuff. just dont know what my next step is, wiring harness? keep in mind i want to run as much electrical as i can internally. if anyone can just point me in the right direction that would be very appreciated. and if anyone knows any shops or cool dudes that know their shit in the Oklahoma City area that are willing to give some advice or lend a hand to a newbie that would be awesome too.

 

[figure8]

Some more info would be helpful. Are you still running the TCI box? Gonna go with a Pamco and PMA? What are as far as electrical are you wanting to keep? Lots of good diagrams here, just need to know what you want to do exactly.

 

[Chris_AWV_93]

yep the TCI box is still on it, what pros are there running the pamco and PMA vs the original TCI box? im thinking of just running headlight, tail light and rear turn signals as far as lights, im not gonna do any fancy electric start or anything i want to keep it as original as possible. ill post pics in the morning.

 

[figure8]

If the tci box and original charging system still work then go with it. There aren't pros to running a Pamco and PMA, it's more a popular thought. Post some pics in the morning and I or someone else will help you along. It's better in my opinion to redo the wiring from scratch rather than salvage the stock wiring harness. A simple check on the charging rotor and brush set might save you some time later on...

 

[figure8]

Although I will say, a Pamco unit is an excellent investment and Pete himself offers fantastic trouble shooting here on the site.

 

[fredintoon]

Hi Chris,
a Pamco has to be paid for and if your stock iggy still works the cash you don't spend buying one can be spent on chrome plated billet machined bling, eh?

 

[Chris_AWV_93]

yea stock ignition is still good, im gonna try to tear everything out today or tomorrow. i got some pics here for ya.

 

[Chris_AWV_93]

so ive started tearing out everything. ive also decided to go with the pamco ignition and PMA, gonna order them next week along with a wiring harness from mikesxs, new headlight, tail light, turn signals, battery and battery box. ran into a bit of trouble with the charging rotor and the wire bundle that runs up into it, the two screws holding it onto the bike are stripped beyond belief, i spend a good hour trying to get them out but they didnt move at all, gonna get back to it this weekend and try to figure something out.

 

[fredintoon]

- - - ran into a bit of trouble with the charging rotor and the wire bundle that runs up into it, the two screws holding it onto the bike are stripped beyond belief, i spend a good hour trying to get them out but they didnt move at all, gonna get back to it this weekend and try to figure something out.

Hi Chris,
you mean the stator not the rotor, right?
Gotta say there's things that should have crosspoint heads on them but an XS650's stator bolts ain't one of them.
If all else fails, shove a 5mm drill bit into the cratered out crosspoints and drill the heads right off them.
Now you can slide the stator off the screw shanks and grab them with a vise-grip to thread them out.

 

[Chris_AWV_93]

good news got the stripped screws out, just waiting to order new PMA and ignition, lights, wiring harness and battery. So as far as the wiring harness goes, that has everything i need to wire all electrical components to the battery? can you internally wire it?