Minimal wiring

Hey,

I know this topic has been discussed several times but I was not able to find a good thread with pics etc of the actual harness.

I was wondering how you approached it?
I bought a second wiring harness which I am planning to open up and just use the wires I need. Wiring diagrams show what goes where but not necessarily what pin to use when connecting to e.g. the ICU.

Any ideas / experience reports are welcome.

I will tackle this over the weekend and take pics

 

looks like the colors are there but you better check each one before you snip anything.
do you plan on using the oem plugs or getting new ones, you might get places where a six place plug only has one conductor in it.
tack/tape/nail the donor harness to a board in roughly the layout of the bike. then go one wire at a time, mark the wire at both ends and mark it on your print. when their all marked off the print, start snipping.

 

Thanks for the pics. I came across them before and they are already in my garage
Yes, I am planning on using the original connectors, even the original wires depending on their condition.
The key ignition will be relocated, but the rest will stay where it was.

I think the most complicated part will be to identify all the different wires coming from the engine. Unfortunately I missed to label them.
But I haven't really spent much time looking at it.

 

i'am planning on doing it this winter with new wire and new waterproof plugs.
from the engine is three alternator white wires, the ignition pick-up wires, three of those and the big wire to the starter
it's kind of like painting, preparation is the key

 

I thought about new wires. But considering all the different colors I'd have to buy to do it right, I figured it would be cheaper to just buy a second harness and reuse it's wires and connectors.

Guess I have to figure out where to put my key ignition first

 

Ok, I got started and labeled most of it. Last questions before I identified everything. All coming from engine..



What are the two bullet connectors and what plugs in there?


The connector on left with three white wires is alternator. What is the big single one?
also, what are the other two connectors? One of them should be coming from side stand switch. And the other one?

 

Looking at the wiring here http://frankjohansson.com/stuff/xj550/XJ550ElectricalDiagram.html the brown and green appears to be coming from alternator as well. The other one is side stand switch. Does that sound about right?

 

Think i got it figured out.
top bullet connector (black/white) goes to side stand relay.
the big white bullet is the neutral switch. But it ties into sky blue.

I still haven't figured out what the blue bullet is. It's the lower one in first pic.

 

From Lens Ultimate Relay, Switch, Sensor, and Diode Guide:

http://www.xjbikes.com/forums/threads/the-ultimate-relay-switch-sensor-and-diodes-guide.27543/

Transmission-in-Neutral Switch:

- on XJ550 models:
* factory wire diagrams show a main harness Sky Blue attaching directly to the switch ---this is not correct. The Sky Blue wire is on the main harness only, and it attaches (via a bullet connector) to a solid Medium Blue wire that attaches to the switch itself.


- on XJ650 thru XJ1100 models:
* factory wire diagrams show a main harness Sky Blue attaching directly to the switch ---this is not correct. The Sky Blue wire is on the main harness only, and it attaches (via a bullet connector) to a Dark Blue wire that then runs to the neutral switch itself. This Dark Blue wire is bundled within the pick-up coils harness.

 

Hmm, if the blue one is the neutral, what is the white bullet then?

 

I can't really tell from the photo what part of the harness that is. However, that white wire almost looks like an add on or repair from a previous PO. I don't remember seeing any bullet connectors that did not use a crimp and strain relief in the stock harness.

 

It is coming from the engine.
Need to look at the wiring loom and see if there is another bullet connector and where it goes from there, but don't remember seeing one.

 

approach from the other direction, identify the wires that are on the MWD. doesn't matter what all the other wires in the harness do, you don't need them.

 

Well, that's true, but now that I know, I want to find out
I will try to follow that wire down to where ever it goes next time I am working on bike

 

hi guys interesting read so far. I am trying to start from fresh all i have are the 3 wrapped wires running down and the front sprocket area. Can anyone advise what these 3 are ? one of the wrapped wires has a Grey,Dark Blue orange and black- where would these go to? and also the thin wire from the triangle ? thank you

 

Did you check the URL in one of the first threads? I figured most of it out using that page. That and my manual wiring diagram to double check by looking where the wire goes.
I have an 81 550, not sure if there are different colors for different models and years.

 

thanks saftie it must be me being the blonde girlie thing. i did see these but couldn't see the 4 wires Orange, Dark Blue,Black and Grey hence the questions. Manuals are great but you cant ask it question when stuck......

 

Lol, no worries. I am blonde too most of the time, too. And with bikes 30 years and older, I never really trust what is on there or if a PO has changed things. Let's see what the others have to say, maybe they can help you.

 

just from where it's at, i'd say that's a neutral switch

 

thanks Polock... 1 down 3 to go

 

the FrankJohansson link is very useful but still doesnt show 1 of my black plastic wrapped wire with Orange,Dark Blue, Grey and black........

 

Hi saftie, can you help with the wires that should connect to the 2 blocks of pins on my TDI 14-05 4U8-10 . I have hardly any wires or connectors, any manual only shows the coloured wires going into the TDI but doesnt show which row top or bottom or left or right hand block.

thank you

 

Here you go

 

This is on a 81 xj550.
dunno what bike you have and if the TDI is the same. Didn't take a pic of the ID.

 

thank you, so going by your photos the left hand block of 5 pins has- orange pin 1 black pin 2 along top row. black and white 2nd row 1st pin and grey in 2nd pin
right hand block top row has red and white 1st pin and orange 2nd pin. bottom row is black ? ist pin and Grey ? 2nd pin is this correct
My bike is a 1983 xj550 UK bike.

 

Correct.

 

Well, I started taking stuff away. So far so good. All wires look good and undamaged. I hope to finish before the weekend and to put it on the bike on saturday.
Seeing in person what is really left in the end, I should have just rewired the entire thing from scratch. But then I would have to touch the connectors as well, which I wanted to avoid. Could be a project for the winter.

 

Finished up wiring, still need to find new location for ignition and wire that one in. Problem is that is only have 3 fuses left instead of the shown 4.
Poop

 

I think I am missing the one for the headlight. I am still waiting for the handle bar control switch, I guess I will have to figure it out then.

 

Well, I just decided to do it from scratch.
I did remove stuff from the original harness but now that I am looking at it again a few weeks later, I am scratching my head.
I finally got the left control switch today and have all the pieces now to start again. Besides, this will give me the chance to clean up too long wires and the mess I have with all the connectors that are stuffed inside the battery box.

 

hey, in the white diagram, there is a starter switch. and in the green one there is a starter switch and a kill switch.
what is the starter switch? is that the starter button on the right hand control?
and what is the kill switch? is that the engine off switch on the right hand control?

 

you're correct on both.
i tried real hard not to be a wise ass on that one

 

Oh hey, no worries. Be a wise ass if you want and need to I know some questions are silly or are asking for it.

But yes, figured it out by using my brain. It hurt but all good.

Thanks

Oh hey, there are two red/white wires for kill switch, does it matter which goes to fuse box?

 

no
but maybe if it's hooked up backwards, it's a start switch sorry

 

I guess I'll see
Working on everything now.
Hope I can at least test lights later today or some time this week.
Should have done it right the first time...

 

Well, I only made the tail light go on. But that's easy bc it comes straight from ignition. Headlight doesn't work yet, I guess I still need to figure out the correct wiring for the replacement dimmer switch that I have. Will need to check again tomorrow.
I am probably just missing a ground somewhere. I only put everything together as a test

 

Keep in mind that diagram was intended as a bare minumum that could be modified to suit the particular needs of a rider. I think the person that made it used a frame-mounted ignition switch and start button, and killed the bike with the igniton switch without having a seperate kill switch (which is stupid IMO, but does make the bars look clean).

 

think about some headlight relays, the way it's shown the hi/lo switch carries the current for the headlight, that will work but your going to loose some voltage in the switch contacts and the longer wire it takes to get there. With relays the switch controls only the relays small current draw and the relays can be wired with #14 wire and are more suited to the headlights current demand.
the headlight will be noticeably brighter

 

Thanks Moe and Polock.
The green diagram has the kill switch, which I am putting in. I am also adding turns.
I am actually used to shutting off bikes with ignition, not cut off switch. But it is a good feeling to know there is one on the bike.

I hope to get this done soon. After this, I only have front brake and seat left to do.
Tank should be back in a week.
Was hoping to take her upstate NY in two weeks when I go on vacation. Was going to stop by Hogfiddles. But looks like she won't be ready. Not enough time. At least I can take my Agusta.

 

Ha, got the headlight, lo and hi, to work.
It was the one wire I did not test ... d'oh.

 

Looking at the two diagrams at beginning of thread, they are slightly different and I ended up mixing both bc I didn't realize before.
Looking at the green one, I can't get my horn to work - however I was using the wiring of the white diagram.
Not sure if there is a difference or what it is. I believe there shouldnt?
I wired the brown wire from rectifier to brake switch (as seen in white diagram) and also added the horn. According to the green diagram, i can do horn and brake using the same wire. However this doesn't work. Using the headlight wire, I can make the horn work.

 

Also, in the green diagram, the ignition is part of the wire chain going into the fuse box. In the white diagram, it is not, at least not before it hits the fuse box.

 

maybe you had it on the switched side of the brake wire? Seems it should have worked but it works now and that's the main thing. anything else you put on it should go on the brake fuse, try to keep the load spread around

 

well it works when i use the wire that is supposed to go to the headlight.
i will try again today.
if no luck, i will change everything to just the green diagram wiring.
should only be a small change.

 

cant believe i am having such a hard time with this. everything is actually pretty straight forward. but i guess the different colors of the wires on my replacement switch with no color code explanation doesnt help.

 

d'oh. all good. i didn't pay attention and used the wrong end of my brown wire to connect to battery. you know, the one that doesn't do anywhere....

 

when you're testing something it's a good idea to use a battery charger rather than your battery. the horn might sound sick and the lights will be dim but you won't burn anything down.

 

Good advice, thanks. What would the setup look like?
Good to have the fuse box as well. Already shortened something yesterday.
Lights and horn are working, now adding turns.
I still need to figure out how to rest the starter without actually cranking the bike. Or at least I should put oil in.

Double motivated now, my tank came back today. Omg it looks good

 

just take off your +battery wire at the battery and clip the charger + to the wire, then clip the charger - to the - of the battery. nothing is connected to the + post of the battery.
if you want something to take the place of the starter, go the auto parts store and get some little marker light, maybe a universal one for a trailer or something. if it only has one wire, put another one on its mounting bracket. now you have a 12v test light. take the big wire from the starter hook it to the test light, the other wire from the test light to ground.
you're going to need a 10 amp charger, one of those tender/trickle chargers ain't got the beans.

 

Thanks. So instead of battery I actually have electricity hooked up? Oh dear. Sounds scary...
And thanks for the starter test scenario.
Should be done with turn signals tomorrow and need to test start switch. After that I should be good with everything.