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xs650 > > Motorcycle Systems > > Electrical > > building a wiring harness?


building a wiring harness?
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chilliwackwestie
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Joined: Sep 26, 2008
Posts: 37
PostPosted: April 5, 2009, 4:09 pm    Post subject: building a wiring harness?
Has anyone out their made their own wiring harness?
the harness on my bike has been molested beyond repair.
their must be a much simpler way of wiring this thing.
any thoughts ?
Cheers
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xsleo
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Joined: Oct 28, 2007
Posts: 1528
Location: Earlville NY
PostPosted: April 5, 2009, 7:40 pm    Post subject: Re: building a wiring harness?
I have rewired my 75. I am using 6 fuses. That way each section of the system has it's own fuse.
The only thing I'm using from the stock system is the switches, ignition, starter with safety relay. I have all the lights working.
I started with the charging system, from there I added the starter and ignition. Once these worked I started on the lights.
I am having trouble with the charging, every thing test out ok, just erratic readings at the battery. Voltage jumps all over.
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"You live more in five minutes on a bike than most people do in there whole life"

'75 XS650B with a 79 dual disc front end, rear disk brake, Chrysler reg, Radio Shack rect, LED tail/ brake and turn signals.
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tintin
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Joined: May 07, 2007
Posts: 96
PostPosted: April 9, 2009, 12:54 am    Post subject: Re: building a wiring harness?
I'm just finishing my wiring up - all from scratch.

I'm using:

ikesXS regulator/rectifier
Boyer ignition/coil
Yamaha YHA205 handlebar switch control (all in one side - nothing on right)
Kickstart only
2 pin flasher relay
Honda CB500 ignition switch

I started last June Rolling Eyes Just finishing it up now. Took the last 7 months off though Wink

As you can see I went the tedious OCD route and sleeved everything in braided sleeving, heatshrink out the wazoo etc.

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Last edited by tintin on April 9, 2009, 12:57 am; edited 1 time in total
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tintin
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Joined: May 07, 2007
Posts: 96
PostPosted: April 9, 2009, 12:55 am    Post subject: Re: building a wiring harness?
Couple more pics and the wiring diagram.

Only part of this left is the Boyer ignition installation. All other wiring is done and tested fine (haven't started the bike yet though, so the charging system isn't confirmed yet!)

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