80 XJ650G Gauges Removal

I am making a bobber and want to remove gauges and want to know if I need to cap off the lines I take off?

 

tach cable drive at motor = yes. (Mechanical tach assumed.)

unused electrical connections = yes

 

How do you go about capping them off?

 

You will not need to physically cap the unused connections off but it would be wise to pack the exposed connector ends in dielectric grease and then stuff all the unused connectors into a small plastic bag to protect them from the elements. There are a few ways you can do this that may/may not be esthetically pleasing but you sure don't want those connectors out there waving in the wind. If you are hard core, you could also cut off said connectors and cap the exposed wires (one at a time) with heat shrink caps (available from McMaster Carr or other supplier). Just be advised, once you whack them off, they are a PITA to reinstall if you want someday to return the bike to factory trim.

 

When I bobbed my scoot, I decided to only have a speedometer and the neccessary indicator lights (signals, nuetral and bright beam indicator) I don't need no stinking tach anyways...
All the neccessary wires were left out in the open to get at. The rest of the wires, were labeled with tape and a perminent marker (for future reference - ya never know) then I taped the ends off (so they don't short out on anything) and tucked them either inside the headlight housing or under the tank. I secured them with wire ties to keep them in place. Simple and effective.

 

Thanks for the info on the wires but I pretty much had that down being I am a low volt tech. I am more concerned with the TACH hookup on the engine.

 

You shouldn't need to cap off the tach boss down on the head, it has a seal that should be just fine without the cable in place.
Go for it!