Simple wiring diagram. How does this look?

Brett

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I'm coming to the end of 18 month build on my '81 xs650 project and I'm half way through the wiring.

I'm not running a starter or turn signals and trying to keep things as simple as possible.

Below is the wiring plan I've put together with a lot of help from diagrams on this site (thanks to everyone who has posted a diagram!).

My main concern is the black wire from the bushes. It's a later model bike with combined rectifier / regulator but there is a black, as opposed to a brown wire going from the brushes to the rectifier. (From what I can tell, the brush with the black wire is not grounded if that means anything). I've checked the old loom as much as is possible (it's a cut up mess!) and it seems it was connected to the brown wire going to the rectifier before, but I'm trying to get a better understanding before I complete the wiring and start it up. (I'm using a small, light Shorai 7amp Lithium Iron Phosphate battery. Fantastic thing - but if I short it - it's fried!)

(The battery, ECU and fuse box are held in a small enclosed tank under the seat)

Any other suggestions and constructive criticism would be really helpful!

Thanks
Brett
 

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Unless you're using a latching relay(unusual/uncommon), you'll have to keep holding the momentary handlebar button down for high beams. Front brake (if you have one) won't light the brake light. Otherwise seems okay to me.
 
Thanks. I was unsure about that high beam switch, I'll have to revise that - or look into a latching relay.
 
Thanks. I was unsure about that high beam switch, I'll have to revise that - or look into a latching relay.

The most straight-forward approach would be to replace the momentary switch with a standard two-position on-off switch. If you're trying for a very minimal on-handlebar switch appearance, there's plenty of tiny options; the switch only has to trip the relay, not power the light, so you can use just about any sort of 12V switch/button, as long as it isn't momentary.

Better that than to have a latching relay. Keep the relay simple and standard, like one of the common Bosch "ice-cube" types, and you'll have less problems in the long run.
 
I'm using this switch to keep things simple.

I wanted the horn, kill and dip switches as one unit and liked this switch (shown below, from here
http://www.vehicle-wiring-products.eu/VWP-onlinestore/motorcycle/switches.php. )

But the red kill switch is grounded on the bars to complete the circuit, and I know that the XS650 needs a complete off switch in the circuit due to the ignition system. So I was going to use the light switch as the kill switch and the red kill switch to dip the lights via a relay, but I'll try to come up with another solution.

They do sell a latching relay but it's a complicated and expensive way of doing it.
 

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I used a latching relay in the end and it works well. There are just three wires going to the headlamp.

I have a problem though - it won't start!
I wired it as in the diagram above but I'm not getting a spark (i tested each plug while I grounded them and could not see a spark when I kicked it over.)
I tested across the ignition coil primaries and I'm getting 2.7ohms.
I made up some new coil leads with the correct 5ohm caps and the screw connector with seal at the coil end.
It started before I stripped it down.
There's fuel in the carbs and I sprayed some directly through the carbs to prime it.
(A couple of times it's coughed back through the carbs when I've switched off the kill switch or the ignition key - not sure what that is)
Not sure what else could be wrong - I must be missing something!
Any ideas?? I really want to see it start!
 
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