Xs2 electrical system to be redone

[Trionfo Jimmy]

good morning everyone, this forum is very powerful!! congratulations!
I have a question that most likely has already been asked but in the crowd I struggle to understand.
I start from the assumption that I live in Italy.
well, I recently purchased a 72 xs2, all original but over time the electrical system was repaired because it had burned out, so certain connectors are missing.
my goal is to keep the points but install a pma system to make the bike more reliable.
I'm not a fan of electronics, more mechanics less problems!
I would like to redo everything from scratch because the bike is 53 years old and every cable and wire is dry and cracking.
what do you recommend?
are there basic electrical diagrams?
I'm not interested in having more performance or things like that, I would just like reliability and simplicity.
thank you in advance

 

[Its been a long time]

Personally, I recommend that if the alternator rotor and stator are good, forget a PMA. Fitted with a standard 3 phase bridge rectifier and an automotive regulator, the stock charging system is reliable and cheap to maintain. Only carbon brushes to replace every few years.

I see many more problems here with PMA and regulators than stock systems set up as I described. I set up my charging system that way for less than 30 Euros, it charges fine.

My set up -

https://www.xs650.com/threads/uk-source-voltage-regulator.65543/post-832950

 

[gggGary]

Welcome aboard!
Buy a new replacement harness

and keep the stock charging system with a rewound rotor. Set and adjust the stock regulator and it will probably outlive YOU.

 

[JJames]

Welcome. It sounds like a complete wiring harness is your first step. If wiring. Is not your thing. There may be a plug and play harness available. Hopefully some Xs2 owners will chime in. Ask here before ordering part as there are literally thousands of years of shared experience on this site. I agree with IBALT on the PMA. Do some reading in the tech section for step- by-step diagnosis of the xs charging system. The XS2 is a favorite. Have fun.

 

[JJames]

Oh yeah. We love pictures. Hows about posting some pics of your bike.

 

[Jan_P]

Seems
i fumbled myself these days Mistakes happen
Had poor charging ..like always 40 years 2 bikes
Did go for the final solution new harness
Still poor charging
In with a PMA still weak
By chance noticed that some one dark night installed a 100 / 80 W bulb ca twice according to the manual
via mistake ..
Replaced now have half poor charging 13.5 ish

Over the years with ( few Exceptions ) never the wiring always a connector or switch
And never ( with few exceptions ) the carburetor

So after thinking it over I am at
There are several subsystems using the power System 1 ,,2 ..3
Using only part of all ignition System 1 no light fine 14.4
Switching on lights System 1 ,,2 oooppp ... ss drops .A bit to much

So it is maybe so that some subsystem is partially grounding a bit to much
WHICH ONE ?
Can be difficult to find ..measuring resistance to ground and current draw
Much is replaced but there is still much there from before Blinkers / Key / Brake Switches

SO according to the CSF Rule Cheapest Simplest First rule

If possible service the existing wiring and foremost Connectors and Switches Se if that is a solution
Myself will ride perhaps without lights on for a while But the 13.5 V can be sufficient
Looking for a partial ground

Maybe a re-adjustment
Not so amused to be searching for this
But nothing to be gloomy about
That's how it's always been with cheap old motorcycles Always will
Its a process ..

 

[GLJ]

Welcome aboard!
Buy a new replacement harness
View attachment 350856
and keep the stock charging system with a rewound rotor. Set and adjust the stock regulator and it will probably outlive YOU.

I've used Mikes 72 harness several times and it works very well.

 

[Trionfo Jimmy]

thanks for the answers, I'm happy to have found a group like this, I hope to learn.
so, I'm an industrial mechanic but I don't understand much about electricity, only the basics, I can connect single-phase or 12v cables but I've never worked on motor electricity.
that said, the advice to redo the electrical system in an economical way is very appealing to me! I would need a step-by-step guide but with specific components so as to only move my hands under someone's guidance.
I'll attach the photos in the meantime.

 

[Its been a long time]

thanks for the answers, I'm happy to have found a group like this, I hope to learn.
so, I'm an industrial mechanic but I don't understand much about electricity, only the basics, I can connect single-phase or 12v cables but I've never worked on motor electricity.
that said, the advice to redo the electrical system in an economical way is very appealing to me! I would need a step-by-step guide but with specific components so as to only move my hands under someone's guidance.
I'll attach the photos in the meantime.

Everything you need is here. Take a good look at the Technical Section of the forum. For example, charging system information -

https://www.xs650.com/threads/expanded-charging-system-guide-in-progress.10561/

 

[Trionfo Jimmy]

I found this useful diagram... can you confirm that it is compatible with xs2 1972, so tomorrow I'll check how much they messed up and contact mikexs to order the complete wiring

 

[Jim]

I found this useful diagram... can you confirm that it is compatible with xs2 1972, so tomorrow I'll check how much they messed up and contact mikexs to order the complete wiring

Yes it is.
@650Skull put quiet a bit of effort into that schematic.

 

[Jan_P]

I found this useful diagram... can you confirm that it is compatible with xs2 1972, so tomorrow I'll check how much they messed up and contact mikexs to order the complete wiring

There are sellers in Europe that can have the same wiring It is for me in Sweden typically slower and about the same price to get it from
Mikesxs Nothing against Mike
Customs --And Tariffs the new " Fashion Word "

Maybe there fex

https://www.xs650shop.de/en/electric/wiring-harness-xs-2-tx-650-72-73/24-6571

 

[Jim]

Personally, I recommend that if the alternator rotor and stator are good, forget a PMA. Fitted with a standard 3 phase bridge rectifier and an automotive regulator, the stock charging system is reliable and cheap to maintain. Only carbon brushes to replace every few years.

I see many more problems here with PMA and regulators than stock systems set up as I described. I set up my charging system that way for less than 30 Euros, it charges fine.

My set up -

https://www.xs650.com/threads/uk-source-voltage-regulator.65543/post-832950

Agree. Spend the money elsewhere, the stock setup works fine once it's sorted.

 

[650Skull]

Xs 2 was a basic diagram from factory. Not a lot of safety features as in later bikes. Was the first year for the starter safety relay to cut the starter motor once the bike fired.

Buying an aftermarket loom is the easiest way to go

If.....you rewire...... that safety relay wiring circuit can b changed to its own circuit. *Yamaha did an add on (at the coils) to the 71XSB loom running from the coils, on a brown wire, to the safety relay

Here is the thread where we, (a lot of collaboration from the collective), redone the XS2 diagram.

https://www.xs650.com/threads/72xs2-73tx-wiring-diagram.53244/

Mailman posted a lot of pics of the switches opened up on the last page.
A lot of reference pics from others and original parts throughout that may b handy for references

*

NOTE: yellow wire to stop switches become G/Y
Never did change that

 

[Trionfo Jimmy]

ok, in the meantime I'll order the complete wiring from heidentunning, I'll get ready to do the magnet tests and then I'll update you.
in the meantime thank you very much

 

[Trionfo Jimmy]

Chiedo aiuto a "#è passato tanto tempo". Ho visto che la tua moto non ha un relè di avviamento. Vorrei rimuovere tutto il superfluo e mantenere solo l'avviamento a pedale, le luci e gli indicatori di direzione. Vorrei nascondere il più possibile l'impianto elettrico. Vorrei realizzare un bobber carino.

 

[Trionfo Jimmy]

I'm asking for help from " @Its been a long time ". I saw that your build doesn't have a starter relay. I'd like to remove everything superfluous and keep only the kickstart, lights, and indicators. I'd like to hide the electrical system as much as possible. I'd like to make a cute bobber.

 

[Its been a long time]

I'm asking for help from " @Its been a long time ". I saw that your build doesn't have a starter relay. I'd like to remove everything superfluous and keep only the kickstart, lights, and indicators. I'd like to hide the electrical system as much as possible. I'd like to make a cute bobber.

Sorry, you're mistaken. My bike has the stock start relay and interlock. Maybe you're thinking of another bike?

 

[Trionfo Jimmy]

I didn't see it when you fixed the charging system, my presumption... In Italy, I can't find the Lucas you installed, nor the rectifier. Is there anyone here who fixed the charging system like you did recently? So I'll copy the components. Thank you very much.

 

[Its been a long time]

I didn't see it when you fixed the charging system, my presumption... In Italy, I can't find the Lucas you installed, nor the rectifier. Is there anyone here who fixed the charging system like you did recently? So I'll copy the components. Thank you very much.

This is a typical 3 phase bridge rectifier. There's loads on eBay -

https://ebay.us/m/jVfGWZ

Unfortunately the Lucas regulator I used is now hard/impossible to find. Try something like this one. A member recently used one of these successfully -

https://ebay.us/m/1eEiHp