Aftermarket wiring - handlebar switches etc.

[Gigemags05]

Spin off of this thread, as it kind of evolved. I think I got the solenoid figured out, just have a few more items I’m chasing.

https://www.xs650.com/threads/starter-solenoid-wiring.67291/page-2

I am not 100% sure which terminals to use for my flasher relay. I know which wire from my switch goes to the relay, then I need to provide 12v switched to another terminal? Not sure if the third terminal is used or which terminal each wire needs to go to.


I am just now researching the reed switch and not sure whether or not its necessary.


The diagrams also show a flasher cancelling unit, reserve lighting, as well as a light checker. Not sure if those are necessary or not. If they are not, do i just need to get 12v switched to the headlight on/off switch as well as to the tail light?

EDIT: Comments 2-6 deal with the solenoid question. 7 and on deal with the handlebar switches.

 

[Jim]

One wire (most likely the red/---) is power that winds it's way through the safety relay to the solenoid. The other will be the ground wire that goes to the starter button. Then button goes to ground when pushed and energizes the solenoid.

 

[Gigemags05]

So if I were to bypass the safety relay, where should that red/yellow wire connect?

 

[Jim]

It needs 12V from the battery..... preferably from the kill switch. That way you can't activate the starter unless the kill switch is in "run."

 

[Gigemags05]

It needs 12V from the battery..... preferably from the kill switch. That way you can't activate the starter unless the kill switch is in "run."

Ok, so I have 12v straight from battery to one side post of solenoid, then from other side post to starter. Then the red/yellow to kill switch and green/brown to ground in starter button?

 

[Jim]

Correct.

 

[Gigemags05]

Ok that makes sense. Thanks!

 

[Gigemags05]

I am still struggling with this.

My starter button/lights kill switch have the following colors. I can’t figure out where the red/yellow and green/brown wires from the solenoid should go.

There’s
Blue
Blue/black
Blue/white
Red/yellow
Red/white
Brown

Does the red/yellow on solenoid go to the red/white on starter button? If so where does the green/brown from solenoid go?

 

[Wingedwheel]

What year bike is this? Sometimes the best solution when dealing with PO issues is to start from scratch. It’s not expensive to just replace the butchered up harness.

 

[Gigemags05]

It’s a 1978, but I AM starting from scratch. I can’t figure out what wires correlate. The ignition switch, starter button/kill/light switch, and solenoid are all new.

The head light switch is also new.

Only old parts are the gauges and indicator panel.

I’ve wired multiple vehicles from scratch and this one is far more complicated and frustrating. I can’t even get started.

I have looked at hundreds of diagrams and cannot ascertain the solenoid wiring. Or almost anything else either.

 

[Its been a long time]

It’s a 1978, but I AM starting from scratch. I can’t figure out what wires correlate. The ignition switch, starter button/kill/light switch, and solenoid are all new.

The head light switch is also new.

Only old parts are the gauges and indicator panel.

I’ve wired multiple vehicles from scratch and this one is far more complicated and frustrating. I can’t even get started.

I have looked at hundreds of diagrams and cannot ascertain the solenoid wiring. Or almost anything else either.

Then the question I think you should be asking yourself is, can you do it or not?

These are really very simple 1970's technology. But the price of getting the wiring wrong is likely to be an electrical fire if you're unlucky. So you need to ask yourself if you can do it or not.

Good luck with it, hope it works out well for you.

 

[Gigemags05]

I am beginning to ask myself the same question.

I’ve built multiple vehicles and wired all from scratch no issue.

I even have all the wiring done for the main components on this one. I installed Hugh’s hand built kit. It’s all good.

There is just no info I can find on the wire color correlation from ignition switch, solenoid, turn signal switch/high beam indicator, etc.

 

[Its been a long time]

I am beginning to ask myself the same question.

I’ve built multiple vehicles and wired all from scratch no issue.

I even have all the wiring done for the main components on this one. I installed Hugh’s hand built kit. It’s all good.

There is just no info I can find on the wire color correlation from ignition switch, solenoid, turn signal switch/high beam indicator, etc.

All that information is in the factory manual and there's schematics here. If you have done this before, you'll understand to break the task down into individual circuits and complete them one at a time. If you don't, you can easily be overwhelmed by it. System by system, one by one, it's a lot easier.

 

[Wingedwheel]

Just take it one wire at a time.

 

[650Skull]

That wirng problem solved.

 

[Gigemags05]

I am working my way through it. The wire colors on my new parts are not matching the diagrams so I took the left handlebar switch assembly (light indicator/turn/horn) and right handlebar switch assembly (start/kill/lights) apart to figure out what each color does. So I at least made a little progress there.

From my understanding: The Red/yellow on my solenoid needs to go to the Red/white (kill switch) on my right handlebar, the green/brown needs to go to the blue/white on my right handlebar.

I have a few remaining questions, but probably need to start another thread if I can't find the answers. They're mostly pertaining to a few particulars with lights.

 

[Gigemags05]

Spin off of this thread, as it kind of evolved. I think I got the solenoid figured out, just have a few more items I’m chasing.

https://www.xs650.com/threads/starter-solenoid-wiring.67291/page-2

I am not 100% sure which terminals to use for my flasher relay. I know which wire from my switch goes to the relay, then I need to provide 12v switched to another terminal? Not sure if the third terminal is used or which terminal each wire needs to go to.


I am just now researching the reed switch and not sure whether or not its necessary.


The diagrams also show a flasher cancelling unit, reserve lighting, as well as a light checker. Not sure if those are necessary or not. If they are not, do i just need to get 12v switched to the headlight on/off switch as well as to the tail light?

 

[Jim]

...and done.

 

[650Skull]

Reserve lighting relay tell you when the taillight/brake light bulb has blown.

Personal choice. Some say these features are not needed. I say if your happy to not know if the bulb has blown, more of a chance that car behind you will b a reminder when they rearend the bike.

RLU. Again if the headlight bulb filliment, ( high/low), blows it switches to the other filliment instantly. When it switches to high beam, (if low beam blows), it reduces output, not so bright.
Riding at night, 99,% chance it will save you from a crash. During the day it warns the rider the bulb has blown, means oncoming traffic has a better chance to see the bike coming. Headlight on when riding.

Flasher auto turn off is ok if it works properly. Can b finicky. Not connecting it doesn't affect anything else.

 

[Gigemags05]

Okay, I made a wiring diagram that aligns with the colors from my new parts. I obviously still have some holes in this, and am not 100% sure that the connections I have outlined are correct. Thought you all might be able to give me a little guidance if you had something to look at.

Please note that I have not included any of the HHB wiring, as that part is complete. My main areas of confusion are with the lights.

The areas circled in red are what I have questions on.