Wire Harness - Main - XS650 European - 1977-1986

Niels B

Niels B

2 wheels + engine
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I got my hands on above wiring harness and thought i would use it for my '78 XS650E, it omit the "reserve light units" and the flasher "cancel unit". That's all fine as i can figure out how to turn the signal off and the reserve light unit it not really useful either (except for nostalgic back to original issue). However i can't track down a wiring diagram for any european models on the net or in any of my books as well as on this site, reason i would like a wiring diagram with colors is that it appear the the headlight either had different colors or the harness miss the headlight wiring all together - any thoughts or knowledge out there ??
 
The only diagram I have is a '77 one "for other areas". The only real difference I see is the addition of a small bulb in the headlight for parking. It still shows the canceling unit and RLU.

77-xs-d-other-wiring.jpg

Oh, it also has a "passing" switch that flashes the high beam.
 
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I unfortunately don’t have a Haynes manual but a clymer ( which got a bunch of diagrams from early to late models) however can’t find any matching the colors on the one I have ( which is an aftermarket for sure - thus they may have used wrong colors too. The one I’m building is an early ‘78, thus have more or less same as ‘77 models. What I don’t get is why there would be a color difference between us / aus / eu. The harness I got my hands on I believe is like the once mikes xs sell as an European model ‘77-‘86 - maybe scrap it and either rework the original or buy an ‘78 harness. Either way thought I could save 8
$80 bucks or so and work with the one I have with the exception of the reserve light and the cancelling unit- I’ll see what happens when I get to add it to the frame - maybe by using what I’m certain of will review how the rest goes together :)
 
I did look in the book there is a Schematic
one Early and one Late XS 650 E No mention about Differences European USA
With colors --- I believe i can scan it later tonight if it is of Use please tell

I got an aftermarket loom new ...last summer and it was not much corresponding to the original 1980 I wanted
really poor correspondence .Many hours to figure it out
 
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Jan_P said:
I did look in the book there is a Schematic
one Early and one Late XS 650 E No mention about Differences European USA
With colors --- I believe i can scan it later tonight if it is of Use please tell

I got an aftermarket loom new ...last summer and it was not much corresponding to the original 1980 I wanted
really poor correspondence .Many hours to figure it out
Click to expand...
I’ll take a look of the scan/pic when you get around to it - yes was trying to avoid “guessing” just going through continuity check and marking everything is a pain in the butt - anyhow may have to go that route. Have a bunch of old wiring from various years so I may also try to cannibalize correct wire color and make my own
 
There is one in the back of one of the manuals for a euro single fuse. I will take a pic and post. Can't access my laptop through my phone any more, (?????), so it will b in 2 parts

Won't b home for a while.
 
Niels B said:
I’ll take a look of the scan/pic when you get around to it - yes was trying to avoid “guessing” just going through continuity check and marking everything is a pain in the butt - anyhow may have to go that route. Have a bunch of old wiring from various years so I may also try to cannibalize correct wire color and make my own
Click to expand...

Can it be something
Dont know if European
It is possible to zoom on it ( file ) here when on the computer

XS650E.jpeg
 
The diagram I posted could b for early Eruope.

Is your bike a Euro import??

What I have found. No guarantees

I have a 77D euro diagram on my laptop. A few minor differences
No reserve lighting unit. There is a light checke though
Where. 5T's diagram has a small 6 pin coupling coming off the left handle switch on the Euro they are all bulletconnectors.

Taco; 2 pilot, high beam, and (maybe), a brakeling warning, lights.

Pilot box; 2 turn indicators, neutral and brakelight.

Same as 5T's diagram
Speedo scencer auto off indicater switch. All except Germany???

On the US 77D, Yamaha removed the rear brake warning Sencer mid way through the year.
???? Don't know if they did that with other countries. This next part relates to the rear brake warning Sencer and wiring.

R/W from kill switch has a join run off it to a 3 pin, (small blade) connector. This will b in the headlight
This small connector has Y (headlight), and L/R, (brake pad warning light) Taco pilot lights pig tail

Back to loom
....Follow on the R/W, past connector, goes to safety relay on 3 pin connector, out on a bullet connector to solenoid.

Back to 3 pin small blade connector. In headlight
R/W, (power) goes to pilot light in taco, out on a L/R, (taco pigtail), back to 3 pin small blade connector, runs to rear wheel brake lining switch.

NOTE: somewhere off that wire is a diode, (with power through it off (L/R), on B wire through diode, to W/B wire, that joins into L/W from Solenoid .......the diode will be sticking out of the loom. Can't missit

5T's has a resister, (16), not on my diagram.

I don't know what one will work for you or what you have. ....I can't post from my laptop hense this long tirade and description of the differences.

.
 
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Its been a long time said:
I believe the resistor is part of the reserve lighting system on US bikes. AFAIK, UK bikes never had that system. So in a UK bike there should be no reference to a resistor. I think.
Click to expand...
Yea I think it is for the RLU

There isn't. No resister, a diode. ........Just pointing out a difference if using/looking at 5T,'s loom. Trying to work out differences
OP did say he had different looms he bought/ has
 
650Skull said:
The diagram I posted could b for early Eruope.

Is your bike a Euro import??

What I have found. No guarantees

I have a 77D euro diagram on my laptop. A few minor differences
No reserve lighting unit. There is a light checke though
Where. 5T's diagram has a small 6 pin coupling coming off the left handle switch on the Euro they are all bulletconnectors.

Taco; 2 pilot, high beam, and (maybe), a brakeling warning, lights.

Pilot box; 2 turn indicators, neutral and brakelight.

Same as 5T's diagram
Speedo scencer auto off indicater switch. All except Germany???

On the US 77D, Yamaha removed the rear brake warning Sencer mid way through the year.
???? Don't know if they did that with other countries. This next part relates to the rear brake warning Sencer and wiring.

R/W from kill switch has a join run off it to a 3 pin, (small blade) connector. This will b in the headlight
This small connector has Y (headlight), and L/R, (brake pad warning light) Taco pilot lights pig tail

Back to loom
....Follow on the R/W, past connector, goes to safety relay on 3 pin connector, out on a bullet connector to solenoid.

Back to 3 pin small blade connector. In headlight
R/W, (power) goes to pilot light in taco, out on a L/R, (taco pigtail), back to 3 pin small blade connector, runs to rear wheel brake lining switch.

NOTE: somewhere off that wire is a diode, (with power through it off (L/R), on B wire through diode, to W/B wire, that joins into L/W from Solenoid .......the diode will be sticking out of the loom. Can't missit

5T's has a resister, (16), not on my diagram.

I don't know what one will work for you or what you have. ....I can't post from my laptop hense this long tirade and description of the differences.

.
Click to expand...
thanks for the explanation, pity you can't upload from your laptop as it would be easier to view the color code :)
It's not an euro import, however i have that new harness for an euro model so figured i would just change what i could to make it work, if you are able to attach the schematic to an email feel free to email me at nielsbull@outlook.com -otherwise thanks for the explanation.
 
My problem is I only have internet on my phone. I usd to USB onto my laptop to run the internet through there. For sum reason my laptóp now refuses to recognise the phone. I can't transfer anything of the laptop. Email on phone only.

The main thing on your bike is it will only have 3 wires on the ignition switch, follow them from a US 78E diagram ignoring the R'Y and L/R on the Euro harness
R, from battery,
Br, out to power, horn, reg, exctera,
L. For lights, gauges, tailight.

The US 78E I think got a 4 fuse bank as a mid year change.

Yours being an early should have a single 20 amp fuse, same as the Euro
 
650Skull said:
My problem is I only have internet on my phone. I usd to USB onto my laptop to run the internet through there. For sum reason my laptóp now refuses to recognise the phone. I can't transfer anything of the laptop. Email on phone only.

The main thing on your bike is it will only have 3 wires on the ignition switch, follow them from a US 78E diagram ignoring the R'Y and L/R on the Euro harness
R, from battery,
Br, out to power, horn, reg, exctera,
L. For lights, gauges, tailight.

The US 78E I think got a 4 fuse bank as a mid year change.

Yours being an early should have a single 20 amp fuse, same as the Euro
Click to expand...
Yes mine got a single fuse, rest noted - sorry you are stuck with your phone only !
 
The Standard model never got a fuse block, it always had just the single 20 amp main fuse.

What's wrong with your original harness, just old or all hacked up? I ask because there's nothing wrong with it, and things not needed can be easily eliminated on it (RLU, light checker). It's also not too difficult to enable the handlebar headlight on-off switch full time (just unplug one wire), nor is it that difficult to "fix" the ignition switch so the tail light doesn't come on with it. I've done all that to mine.
 
5twins said:
The Standard model never got a fuse block, it always had just the single 20 amp main fuse.

What's wrong with your original harness, just old or all hacked up? I ask because there's nothing wrong with it, and things not needed can be easily eliminated on it (RLU, light checker). It's also not too difficult to enable the handlebar headlight on-off switch full time (just unplug one wire), nor is it that difficult to "fix" the ignition switch so the tail light doesn't come on with it. I've done all that to mine.
Click to expand...
Well whoever partly stripped this bike before I got it didn’t believe in unplugging the wires - so a large amount are just cut with a wire cutter - the sad part is that beside from the butchering, the harness looks pretty ok - need to replace some of the parts like regulator / rectifier / blinker relay etc - coils measure good and condenstors seem to be in ok condition too. So rather than splicing 20-30 wires I was trying to use what I got ( which is apparently an European harness lacking a few things that’s not needed anyway :)
Just got the frame back from painter before Xmas and I’m consolidating stuff so I can start putting it back together, engine stitting ready to be put in the frame
 

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