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some wiring diagrams

Discussion in 'The Garage' started by inxs, Oct 14, 2009.

  1. nomad07

    nomad07 XS650 Member

    is there a wiring diagram in here that shows the set up for a bike with a battery, pma, Pamco ignition, headlight, taillight, and electric start? or one that has kick only?
     
  2. xschop

    xschop XS650 Enthusiast

    So your telling me all I have to do is cut the wires where they come out from and splice your harness in and I'm rid of everything else? That simple?
     
  3. What I am saying is if you still have your stock harness and you want to slim it down for your chopper. ALL you have to do is hook up your REG/REC plugs Alternator Plugs and cut back your harness . Now you will have the CORRECT wires for your charging system and you will end up with only a couple wires that will need to be hooked up because the remaining wire go to your REG/REC and ALT. Then you can makeup your own wires for LIGHTS/BRAKE SWITCH/HORN/STARTER/POINTS-TCI or you can buy one of my kits that give you those wires. TC BROTHERS sell the wires for year of bike for REG/REC/ALT if you want new. MY harness kit is universal and can be used for POINTS/TCI/PAMCO/BOYER because it gives you the power wire to run them.
    Now my kit comes with NO SWITCHES so you need to buy them or upgrade to a complete Custom harness and you get SWITCHES and the correct TC BROTHER wires.
    My Custom per your bike comes with
    3 wires for head light HIGH/LOW/GROUND
    3 wires for tail light RUNNING/BRAKE/GROUND
    2 wires for brake switch 12 volt POWER/ wire to BRAKE LIGHT
    2 wires for horn GROUND/12 volts from switch
    2 wires for NEUTRAL light GROUND/wire from Light 12 volts
    2 wires for COIL and POINTS/TCI/PAMCO/BOYER and in some cases you only use ONE
    Key Switch OFF/ON /LIGHTS
    Push button switch for starter if used
    Push button switch for HORN
    Neutral light GREEN
    HIGH /LOW switch for lights
    4 Position Fuse Box
    Small box that they are mounted to (you can use it or change to what you have)
    ALL WIRES tested with ohm meter and also with 12 volts
    All NEW WIRES SHRINK WRAPPED and ALL ends tagged for easy install
    I have built and sold over 40 of these I do 2 to 4 a month and I DON'T SELL and go away you will have my number if you run into problems and don't understand wires.
    Thanks Rich
     
  4. e36bmw

    e36bmw XS650 Member

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    houston
    Hello im triying to wire up my 1982 xs650 special heritage, im using the second wiring diagram as refrence,, can anyone tell me if i need to unground my brushes using that diagram thank you...
     
  5. If you have a 1982 you don't need to do brushes its done already . Are you using the TCI box or up grading to PAMCO BOYER???
    This is a wiring for 82
     

    Attached Files:

    • 1981.jpg
      1981.jpg
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  6. e36bmw

    e36bmw XS650 Member

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    houston
    Yes im using stock system..

    Thank you for the input..
     
  7. Retrobased23

    Retrobased23 XS650 Member

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    Can someone help me I'm looking to rewire my 1983 which of all the instructions do I need to follow?
     
  8. figure8

    figure8 XS650 Guru

    If you want to simplify it the diagram right above is what you need.
     
  9. e36bmw

    e36bmw XS650 Member

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    do we need to unground the brushes using wiring above? i ran this wiring this morning and no luck i have no spark.. coil is gatting poer all the time .. i have red/white from ignition box to red/white on coil from there it t's of to brown on rectifier to broshes and of to ignition power im using a car ignition switch.. i need some help pls.... i cap of yellow coming of altenator and i cap off black/white coming out of ignition box...
     
  10. Here is what you need for TCI setup
    12 volts to coil and 12volts to TCI
    THATS IT
    Pickup on alternator goes to TCI and TCI feed coil
    Some guys make the mistake and don't give the TCI power just the coil
     
  11. e36bmw

    e36bmw XS650 Member

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    Hello guys my name is aaron... So here is what i got 7 wire ignition unit type t1d12-03
    5v4-10

    .3 white wires from rectifier to 3 white on stator
    .Blk wire from rectifier to blk wire from ignition unit to ground
    .Brown wire from brushes to brown on rectifier from there it t's to red/white from ignition box then to red/white to coil and ignition unit on/off
    .green from brushes to green on rectifier
    .big red from rectifier to battery
    .orange from ignition unit to orange on coil
    .white/green from ignition unit to gray pickup
    .white/blk from ignition unit to blk pickup
    .white/red from ignition unit to orange pickup
    .blk/white from ignition unit is capped off
     
  12. e36bmw

    e36bmw XS650 Member

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    houston
    ok well good news i came in early this morning to the shop swapped white/black from ignition unit with the black/white and i got spark.. now the only problem i have it only runs if i choke it those that mean mt float levels are to low not getting fuel... ???? and i put the nighlon screws on my brushes dont really know if that is nessesary or not...
     
  13. TwoManyXS1Bs

    TwoManyXS1Bs BBQ Hunter Top Contributor

    Aaron, the nylon screw mod is for the earlier 70-79 alternators, so that they can use the later 80-83 regulator/rectifier system. If your alternator is the 80-83 with the black TCI pickup module, it doesn't need the nylon screws...
     
  14. rudey737

    rudey737 XS650 New Member

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    I have a quick question on wiring for my 81 XS650 hardtail using stock ignition and charging systems. What is this that is circled on the wiring diagram? It's connected to brown & green wires coming from the Regulator/Rectifier.
     

    Attached Files:

  15. 650Skull

    650Skull SSSSSSSSSlither Top Contributor

  16. peanut

    peanut XS650 enthusiast & inveterate tinkerer Top Contributor

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    yeah that diagram is a bit too simplified . Some of the abreviations are ambiguous and not at all clear to someone not familar with wiring and electrical diagrams.
    The key switch is too simplified and unclear. The HL on the headlight obviously stands for headlight but what about the spurious HL above the adjacent cable 'HL select' !

    Most of us familiar with wiring diagrams and electrical circuits would know that it stands for Hi/Lo but that would be far from clear to a novice. if the HiLo switch looked something like a recognisable electrical switch symbol ...it would be clear to everybody.

    Below the HiLo switch there is an unrecognisable symbol to represent the headlight on/off switch marked 'HL on off ' Is that headlight on/off ? or HiLo on/off ?

    Same with the ignition switch ...
    .The brown and green wires as we know are the 12v feed and ground wires for the rotor brushes but there is no symbol or text to state that and the 2x wires are just left hanging in the middle of the page ....They look like they should be connected together ! ...
    .

    It just leaves too much unexplained confusing and ambiguous which defeats the object of helping owners really.
     
  17. rudey737

    rudey737 XS650 New Member

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    As a wiring novice, I was hoping a simplified diagram would help me wire my bike. Turns out I was wrong. Thanks for the help, guys!
     
  18. peanut

    peanut XS650 enthusiast & inveterate tinkerer Top Contributor

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    well don't give up on us yet rudey ;)

    There are lots of experts on this forum just waiting to help you with your wiring.
    If you detail your bike spec and set out what you are hoping to achieve together with whatever mods you are hoping to add then you'll get lots of helpful expert advice
     
  19. rudey737

    rudey737 XS650 New Member

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    I didn't mean to imply that I wouldn't be wiring my bike or that I was giving up asking questions here. I'm sure I'll have some questions in the next week or so as I finish up the wiring. That is as long as I don't find the answers by searching first. I don't post a whole lot because the answers are usually already here if I search by the right keywords. That's how I think I fully understand my BS34 Carbs now.

    As for my set up, it's an 81 motor in a hard tailed 78 frame. Stock ignition system and stock charging system for now. Head light and tail light only. No horn, no blinkers, no neutral light, etc. So, that simplified diagram really does give me a start.
     
  20. 650Skull

    650Skull SSSSSSSSSlither Top Contributor

    rudey737, This may help, shows both the Points and Factory TCI ignitions systems in a simplified diagram.

    chopper wiring.PNG

    Here is another one. Doesn't show the TCi ignition only a points set up.
    I am in the process of working with questions people are asking and applying to some diagrams. There are so many in this thread and some have a lot to be desired but they are there.

    simple wiring.PNG
     
    Last edited: Sep 1, 2016

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