Wiring up newer style tci electrical system on yammy xs650

metalho

Im not going to be an ass and ask a question everytime I go to snip a wire, but was wondering if any of you folks have wired up an xs chopper with newer tci box? Alot of diagrams out there and wish there was a magical plug in loom I could purchase but doesnt look like it. I saw that one of the other members completed a chop the same 81 year as mine. Do you guys have a diagram that your members have been using?

xsjohn

Here is some diagrams I have been saving from this site..........some are simple some aren't ........not sure what would work for you...............problem I can see eliminating the safety relays would be hitting the starter button while the thing is running.........

xsjohn

metalho

xsjohn, thank you sir. Im looking for just that kind of information, (diagrams) alot of people helping and am saving all of it while I think about how to wire this relic. Thanks again.

nixon186

i just wired my 83 up yesterday in about an hour using the bottom schematic. most wires are already connected. the two coil wires had to be snipped to get around all the bs in the factory harness. also, the brown wires and the red/white wire had to be snipped and soldered. im not running electric start or turn signals but i still have to run my brake/tail wires and headlight wire. it was much easier than i anticipated.

metalho

Ya, thats kinda what I figured. New I would have to do some snipping and legthening to hide or reposition.

nixon186

i didnt have to shorten any wires. all the wires that were already in the right sport were about 18" long(from what i remember). i made a faux oil tank out of a fire extinguisher i cut up. its 5" in diameter and 8.5" wide and i fit the wiring and tci box inside with ease. i mounted the rectifier in the stock location and welded a bracket for a coil right above that.

nixon186

btw...my stock wiring harness is hanging from my wall and it looks untouched. you literally cut away a majority of the harness.

metalho

Can understand that. Figured once I got past the important plug ins like the tci box, regulator/rectifier, coils..... I would end up with only afew wires to hide down the back bone. Man it sure would help a butt load if you had a pic of how you organized your electrical.

nixon186

i'll take a pic tonight or tomorow night depending on how late i get stuck at my shop. if you haven't already, undo the tape on the harness. you only have to do it between the tci plug and regulator plug and you'll see how easy it is. print out the lower schematic and look at it as your doing it. ignore all the lighting and switch related stuff on the diagram.

nixon186

like this...

metalho

Hey cool dude! Your ok!!!! Thanks, Cory.

metalho

Will be sandblasting frame and springer forks today. Purchased clymer book for 81 xs, found a left hand header at bent bike out in the bone yard. Also powerwashed motor off to inspect cases for cracks.

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Yamaha xs650