1981 Yamaha xj650 wiring

Hello there, I have a Yamaha xj650. That is bobbed out that I worked on and fixed mechanical issues on. My current problem is the wiring. The wiring on it is sloppy and a total hack job. And while I was riding it ended up dieng on me. Nothing works now and the engine doesn't crank over. I just purchased a new wiring harness off eBay. I can do mechanical things on the bike, but electrical I'm not too good at. I'm just wondering how everything will fit together and how to rewire it correctly. I can post pictures upon request.
Thanks

 

do you want to do minimial wiring? there are posts on it with diagrams

 

standard wiring diagram
http://members.tripod.com/dave_jack/wiringdiag/d7a.jpg

http://members.tripod.com/dave_jack/wiringdiag/d7b.jpg

component key
http://members.tripod.com/dave_jack/wiringdiag/d8.jpg

 

did you upgrade your old glass fuses?
also you may want to check your clutch safety switch,side stand safety switch neutral safety switch.
all can be bypassed to test them

when you remove the old harness take photos of routing and wire ties all connectors

thread on clutch safety switch
http://www.xjbikes.com/forums/threa...tch-switch-by-just-looking.30354/#post-261972

if you do not have a meter get one you will need it

 

when you say nothing works do you mean that?
turn key on do you hear relays click? does your tail light light up?
in neutral does your neutral light come on?
no horn, no turn siginals?
you need to test your battery voltage.
you need to test voltage at your fuses with a meter both sides of the fuses and on the clip crimp not the fuse or clips.

 

basically the engine doesnt crank, no headlights, no taillights. nothing lights up. today i stripped all the old wiring off the bike. And i was going to proceed to put the new harness in, but not everything matches up quite right. I have alot of connections that dont have a home. and yes i want the minimal wiring

 

Did you check for a good ground , or main power cables to begin.. I know it's kinda late for me to be asking now, as a rule check out the simplest things first.

 

link to min wiring diagram see photos in first post
http://www.xjbikes.com/forums/threads/minimum-wiring-harness-help.72084/

check your ignition switch has 3 wires power 2 wires are power out

 

the grounds i am going to look over today, and all of the main wires have are plugged in with some exceptions that do not match up.

 

get a piece of ply wood and lay out your old harness on it use nails and wire ties to hold it in place.
mark all your connectors and put markings on the board for each one and wire runs too .
diagram on board where the go to and from.



then you open it up and start stripping away the wires you do not need.
or you can use the layout for a pattern do it twice on the board one for old harness second for a pattern to build new harness
buy some wire and build a custom one adding some extra wire lenght for crimping mistakes .
you may also be able to eliminate or relocate some of the
connectors

 

Does anybody have pictures of there minimal wiring?

 

yes

 

What i mean is on there actual bikes...

 

Ive seen this many times but does anybody like have pics of there actual minimal wiring harnesses they made themselves on and off the bike

 

It's not going to look much different from the factory harness. It just has fewer wires.
Is there something specific that you're looking for about the layout or routing?

 

Chacal has a listing on wire and how to Id the size as well as all the stock connectors and connector bodies.
XJ PARTS CATALOG, SECTION D: ELECTRICAL SYSTEM

 

you're my favorite

 

how about simple wiring a blade fuse to a toggle switch to headlamp from battery positive then ground?

 

Get a manual!
Hayes makes a great one, which includes a wiring diagram and loads of troubleshooting tips and tricks. With enough patience you can learn anything.
I had an awfully old and chopped up wiring harness from the previous owner, and I basically redid the entire thing. I took my time to map out on the bike, wire by wire, where I wanted to run them. I'll be locating all the gear under the seat, mounting the rectifier, fuses on a pan I'll beat out of some sheet metal. I'll wrap the cables together, and I'll have a custom harness simply by following the map of the wiring diagram in the Hayes manual.
Persevere with patience! Take care to make connections tight and sealed, crimp with enough bare copper, and leave yourself a little slack. You'll have a sweet, reliable ride when you're done.

 

There's also a post about testing your ignition circuit out there, but I'm leaving my toilet now and don't have time to find it for you.

 

fixed used toggle ,two wires one through positive other on neg..on.off.on switch..works fine just double check whether off or on is essential..

 

Are you talking about the headlight circuit still? Running that much current directly through a switch will lead to the switch failing fairily soon. Headlights should always be wired with a relay.

 

...april 2 n switch still fine...

 

My progress

 

I'm confused as to how the kill switch kiss the power? Shouldn't it be between the power to the coils?

 

ignition fuse supplies voltage to kill/run switch then it goes to tci coil and solinoid

in the color min wiring diagram that is how the kill switch is installed . in the bw drawing there is no kil switch just the key which supplies power to fuses

 

I ended up installing it in the power switch to the coils, it works, now my issue is, even if battery gets disconnected it still runs.... What have I done wrong

 

power switch is ignition switch with key? (just to be clear)

which wire ? not the red one it always has power brown wire (Br) or blue wire (L)

this drawing?
R(red) wire always hot from main fuse, when key is turned on it supplies voltage to Br(own wire to the fuses, and b(L)ue wire for tail lights

do you mean literally "even if battery gets disconnected" ? if you hooked to the red wire you are running off the alternator. never disconnect battery

kill switch wants to be directly after fuse before tci ,coils ,and solinoid. if it is after tci, switch could still arc and keep bike running.

 

Yes keyed ignition, should I swap red and brown wire off the ignition so it doesn't have constant power?

 

red wire is always hot from main fuse, and sends power to brown and blue wire nothing should be connected to the red wire but main fuse

red is input brown and blue are output

 

OK, so as I look at it, I have red running to igniter, pig tailed to started solenoid. Is that correct?

 

from brown wire on key switch connect red/white wire to fuse then red white wire to ignihtor, solinoid and both coils just like drawing

 

OK everything is rewired to the brown. Now shuts off when key is turned off. Positive piece of metal that comes from solenoid that connects to the battery is broke so I stuck it behind the positive terminal. Before I rewired it, if it popped off the terminal it would kill the kill the bike. Now it will still run. How do I fix this? Is it running off the alternator? If so what is wrong

 

Followed wiring diagram but bike still running off alternator and not the battery, what am I missing?