Just removed my wiring harness...your input please

[lopejd01]

So I bought my 77' last year and started working on it to turn it into a cafe. The problem is the PO had the wiring harness all chopped up (well mostly just the headlight rat nest). I looked at probably 10 wiring diagrams for hours with a face like this: and this : So I decided, rather than spend all this time slicing and trying to hide a 5lb harness, I'll just remove it and start from scratch.

So..I've looked at some simplified chopper diagrams and looks pretty straight forward. Only thing is I want to run signals. Kicking is fine with me though. If anyone has a diagram they recommend for its easy to understand simplicity, please post it.

Also, I'm going to replace my reg and rec unit with a combined reg/rec unit from a special to save space.

I think the PO may have removed some of the elec components so I'll probably have to scrounge ebay. I have a few components though that I'm not sure what the hell they are. Theres one component thats about the same size as the reg (yellow,red,black,red/white) and theres a little black box that looks like it might hold a fuse, but doesnt open (yellow, green/white, black)- anyone know what these two components are for?

any information you guys have, I appreciate it. and if theres anything you recommend I do while I'm this deep in the woods, let me know

Thanks.

 

[speez]

start with the basics, what ing. system are you going to run? ele.start? and for the rec/reg the you have isn't compatible with 77' stator you would need to modify it or swap it for a newer 1 or get a 1 piece reg/rec unit for older xs's

 

[lopejd01]

The reg/rec unit from the special should wire up. from the diagrams I've seen, all I need to do is slightly change how the stator/rotor is getting power and to unground the brushes with nylon screws.

and to make my life easier, I'll be kicking only.

 

[grepper]

If your keeping all the stock electrical components, just buy a new harness from MikesXS. Plug it all back in and your done. The money spent will be well worth the trouble of trying to recreate a stock harness.

 

[lopejd01]

If your keeping all the stock electrical components, just buy a new harness from MikesXS. Plug it all back in and your done. The money spent will be well worth the trouble of trying to recreate a stock harness.

I'm not going to keep all the original elec. components. Just what I need to kick and have lighting. Some of the simplified diagrams I've looked at look pretty simple. But hopefully someone has one that incorporates using signals too and is a trusted and used diagram.

 

[grepper]

OK then,
Well Check out the wire diagram thread http://www.xs650.com/forum/showthread.php?t=61

I Created my own with signals and all.
This is pretty much it with a couple of changes. The Bike has a Pamco Ignition now. But you can probably get the idea. After the key switch there are two wires. One going to the ignition system and one going to the lighting.

 

[speez]

try this u never said what ing.system u'r going 2 run..

 

[lopejd01]

try this u never said what ing.system u'r going 2 run..

Sorry, I'm just going to use the stock points sys. I may upgrade to a pamco later on.