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Electrical Work

Discussion in 'XJ Technical Chat' started by BK82XJ, Jun 15, 2010.

  1. BK82XJ

    BK82XJ New Member

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    First let me say thank you to everyone here for all your help and being so giving about your experiences and guidance.

    Now on to the dilemma. Electrical problems. Due to issues like the ones I am showing in the photos I have decided to rewire my bike. This has started as a commuter bike and has now taken on a life of its own as a project bike. I just dropped my $10 in the mail for the XJCD and when I get paid on Friday I will be ordering a new fusebox as so many of you have recommended.
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    I hope I'm not being unrealistic but being that I have run all kinds of telecom wire in everything from an ice fishing shack to a 30 floor high rise I figure I should be able to handle this with the proper diagrams. My only question is should I do the whole bike in 12 GA or should I go to 14 for the smaller stuff as it appears was done by the factory?

    I bought this bike last fall, 1982 XJ650 Maxim, and it has been electrical short-a-rama so far. At this point if it was a structure I would rewire it so I am applying the same logic. Thanks again and a wish me some luck!
     
  2. mestnii

    mestnii Member

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    My bike actually even has some 18ga wiring on it from the stock wiring harness.

    The way I understand it, going to a thicker wire isn't bad - it's going to a smaller size wire that causes issues.
     
  3. wizard

    wizard Active Member

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    have you taken the sheathing off the loom? that clamp on the browns is stock, you could tidy that loom up & save a buch of agro (all the connectors).
    when I start a resto I strip the loom to that state, check each wire, then re-wrap the loom.
     
  4. cturek

    cturek Member

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    I'd look for a replacement wiring harness on fleabay. I found one for like 20 bucks I bought just for a spare. It came with the coils too!
     
  5. Robert

    Robert Active Member

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    I'd hunt up a replacement from flea-bay. The stock harness used 18 AWG for just about everything (with a few very obvious exceptions). Your XJCD will have the diagram that will show you what size wire is used where. The fun part is that it lists wire gauge in millimeters, not AWG but this shouldn't be cause for worry, it's simple really. The bigger the mm size, the bigger the wire gauge.
    On the other hand, if you are installing a new fuse block and want to rewire the bike yourself, more power to you!
    Best of luck and get familiar with Amp (now part of Tyco) Fast-on connector contacts (available from Digikey.com or Mouser.com).
     

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