Custom Wiring Harness

ok ive been looking through old threads and I cannot find a wiring diagram or anything like that for a custom harness.

the stock one os junk and looks like crap. I want just enough wires to make this thing run, have a head light and brake light and blinkers. I know there are quite a few people that have asked or are looking for a diagram to help them out. does anyone have one sketched up already or can someone make one for me. I have a 81 750 seca and its being chopped right now, so no room for excess wires, thank you

 

xjcd, hayes manual, or there's a few threads on here that link to other sites that have downloadable manuals.

you just need to make sure the gauge of the wire is big enough for some of the high amp stuff. starter, starter relay, battery, ground wires, headlight relay.

and basically you just need to hook up that stuff. start button, ignition, etc.

 

well, theres so many fuses and relays and crap that I dont want in there, i'll put a slimmer inline style fuses in there but I just need to know what wires I need to make the bike run, and what wires control my lights. no gauges or anything like that. mainly make it run is all, lights I can do my self

 

You do realize that most of the wires in there are to just make it run and the lights work (and charge the battery which I assume you want).

Yamaha didn't just stuff the bikes full of extra wires.

All you'll be able to ditch is the safety circuits (which are under the tank anyhow) and the instrument cluster.

Bottom line, most of it has to stay.

If you need to re-make or want to customize you'll have to get the shop manual and work out what you want/need. There are online versions of the wiring diagram, but they don't show what's going on inside the relays and diode block - so of limited use for your purposes.

 

I have thought about doing that also. After much thought and pondering...I still don't know if it's worth the headache to re-do the entire wiring harness. I have already cut out, soldered and sealed all the plastic connectors so far. And after getting rid of the factory gauges, I got rid of a bunch of wires that I don't need anymore, by cutting them short and tucking them behind the headlight under a plastic cover. There appears to be about 10-12 wires that you could eliminate as far as I can see. It just wouldn't be worth starting from scratch to make a whole new harness to me. If you find the magic diagram, make sure to post it here for the rest of us who like to tinker. PD

 

My bike is a bare bones as it need to run. I have eliminated all of the relays, all safety stuff, and use only the essentials for a running bike. I could seriously ball up my wiring harness and put it in my pocket. Most of it does not have to stay, it just depends on what you deem "essential" and your definition of extra. I have a 4 fuse block-1 for the head/tail lights, 1 for the signals, 1 for ignition system, 1 for my gauge. No sidestand/clutch switch/neutral switch/seatbelt/airbag/ABS/DVD gremlins to screw with me. Get on, push the button, go. NO birdsnest in the headlight bucket. (Actually no headlight bucket.) I used to have a diagram in my gallery, i think i deleted it, i'll see if i can dig it up and repost.

 

Kevineleven, that information would be great if you could find it, maybe we can make a sticky?

 

im trying to make this thing as bare as I can, I came across a set of black drag bars last night with 2 inch risers. I also got a hold of a suicide shifter with an stained oak handle so ive already mocked up the way im gonna mount it, it will be unique thats for sure when im done

 

Here's a list of what's included in the electrical components on a Seca around your vintage...



Here's my question for you: what's essential and what would you cross off the list? Answer that and I may work you up a wiring diagram.

 

Kevineleven, That would be great if you would be so kind to post your wiring harness for us. If it will infact, fit in your pocket, I may just have to re-think the idea of completely re-wiring the bike. I don't mind messing with wiring if I have something to go by. It's probably more of a chore tearing the old harness out of the bike!!
I don't feel the need for all that safety crap anyways. If I could replace the electric starter with a kick starter, I'd do that too! What ever happened to going with just the basics anyway? PD

 

hey PD do you know where I can find other pictures or forums of other bobbers, I am going with some drag specalities drag bars and 2 inch risers with a suicide shifter, im looking for other ideas that catch my eye.

 

gamuru, almost all of it can go... i have been asking the same question for awhile now but gave up because nobody ever helped me. All I, and i think bakomak want is everything to make it start and run, headlight, and tail light

 

You gave up because noone helped you? Are you serious?

This diagram will make a 1982 xj 650 run. It's the ignition wiring, nothing else. The lighting is not shown, and the b/w wire is left unconnected. Alternator/regulator also not shown.

 

You got it pretty close, but you're missing the starter solenoid. You can't not have that...

 

BakoMack
I can build a custom harness but if you have chopped it, I would need to have the frame handy for measurements. You would also need to define what all you don't want on the bike and any additions you would want to add. In the perfect world, I could teach you enough about your system to allow you to make your own. Kick the idea around and we'll look at your bike.
To Kevin and Gamuru, great effort you two. Keep up the good work!

 

Here's your most basic wiring diagram. It's got a starting circuit, a charging circuit, forward and reward lighting circuit and a brake light circuit.

 

Thanks Gamuru,
I'll print it out for future reference. That's about as simple as it gets!!

 

Awesome! Thanks Gamaru, I'm sure this will be put to good use by many on this board.

 

Just a quick note. This diagram has no turn signals and the head light/tail light comes on as soon as you turn the key. Better hope that battery's up to snuff and your hand-signals down pat.

 

I'd just wire the headlight to a separate switch to remedy the starting problem and add another curcuit for the signals after the switch. It's a dam sight better than dealing with the stock wiring harness.

 

those are great diagrams for what im looking for, all I need is to have the bike run and head light, tail light and blinkers. its pretty much a stock bike made into to a rigid, ordered my heims and threaded tubes for the rigid MOD, going with no guages and a 87 inch round head light. 3 inch stretched tear drop tank about 3 GAL. bobber seat and hacking up an old FXR harly oil tank to go under the seat for bat and some wiring.

also making notches in my frame tubes to run most of the wiring inside the frame. adding drag bars with 3 inch risers and going with a suicide shifter and im designing my own foward controls in CAD to be made out in billet. it wont be a comfortable bike to ride but will look bad ass. i'll post pics ASAP

 

87 inches is pretty big for a headlight.

 

Yup, 87 inches will get you noticed!! LOL
Can't wait to see the photos.

 

Looks like Gamuru hooked you up BakoMack. Nicely too. Best of luck on that. Shout if you need help.

 

lol I meant 7 inch head light.

I can do wiring but on this diagram I dont understand a few things I circled in red.

are they relays or something and if so do I take em from the stock harness or what?

 

The cork screw in a circle is a light bulb

What looks like an open door to a room, if it were a floor plan, is an open switch in a circuit.

These electrical symbols never really look like the actual object.

Nice diagram Gamuru !

 

really? hell this outta be easy then, I thought they might have been relays or something

 

on the open circuit switches are these items I can pull from the stock wiring harness or do I need to buy them at a store?

 

You dont need to "pull" them. The starter switch is the start button on the right throttle control. The dimmer switch is the hi-lo switch in the left control, brake switch is located near the front of the rear wheel, on the right, with some wires and a spring connected to it. Just wire everything as Gamuru's diagram says, and you'll be in there.

 

thank you for the advise, I guess im good to go on making this thing then, once the seat gets here I can finish up making it a rigid. I wanna try and run as much of the wiring as I can in the tubes of the bike to give it a cleaner look. I was told by the Harley shop to use 20 gauge wire so I was gonna run 18 gauge just to be safe

 

The Harley shop has given you very poor advice. 20 AWG is fine for your home computer. No OEM manufacturer uses less than 18 AWG for vehicle wiring because of a mechanical strength requirment stipulated by the ASE. Anything less than that is unsafe. 20 AWG is rated at 11 amps for chassis wiring, 1.5 Amps for power transmission, within the current requirements on your machine but I wouldn't bet the barn on it. You are indeed better off using 18 AWG. I would also avoid asking the nut-job at the Harley shop for any more electrical advice.

 

thank you for that, so am I safe with 18 or go a little bit bigger? with as much wire as im gonna use m gonna have plenty of room for wires maby 16 or something?

 

Depends upon the application. Signal lights, no problem. Main supply line, you might consider 14 AWG (good to 32 amps). Anything under 10 amps should be fine with 18 AWG.

 

good to know, im gonna go find out how much wire I need right now, thanks

 

Another consideration is the wire jacket. Wires rated at 600V tend to have very thick jackets, 300V rated wire has thinner (not recommended either).

 

ok, im pulling my hair out right now. I need to know what is the rectifier and what is the regulator?




i see there the 7 wires that come from the silver box but how do I wire the 3 white wires and the green wire into the other box?



and wtf is the ACG? can some one please help me out here. I understand what to do with the red, brown, and black. but im clueless with the other 4 wires, please someone help me!!

 

can anyone help me?

 

The one on the left is the voltage regulator, the right is the ignitor/tci. The ACG is the alternator, you should see the wires coming out of the engine.

 

One of the plugs on the Igniter goes to the pickup coil, the wires come out from the left crankshaft cover. The wires from the other plug go to the coils.

 

haha I was so frustrated yesterday I left work early and started working on it again, after about 3 hours of staring at it I saw the wires for the pick up coil and alt. sitting on the desk with the motor, then it all made sense lol

im about half way done with it now, all I need to do now is the wiring for the lights and im done. it also didnt help I had the wrong connector plugged into the ignitor box thats why the wires arnt the right color, took me long enough to figuire that one out too

 

any updates on this?

 

Yeah, any updates? I'm curious as all h*ll to see how this is coming out...

 

Im about 50% done with my new "minimalist harness" using this diagram. I will post the results when Im finished. The only thing Im doing different is no turn signals, and a 3 way ignition switch so i can manually turn on the headlight once the bike is cranked.

So much great info on this site!

 

one of the easiest looms to make...i make them for quad bikes, and if you use OEM connecter plugs you end up with pretty much the same number of wires as stock. The wires to the instument cluster dont account for much, and the rest are pretty important! Its the handlebar switches which require all the bulky wiring.

 

hey guys i'm new to the forum i was tring to use your wiring diagram but i need the key i don't understand what the letters mean my cpu has differnt color wires then what your diagram shows how do i know what wires to hook up also i think my rectifier has diffrent colors also i have an 1981 seca 550 hardtailed, mini apes, peanut tank, solo seat the guy who did the hardtail just stuck everything up under the seat so i decied to just rip everything out and use the one ya'll have please help i need to ride

 

The colors on my rectifier were a little different than on this diagram, but I just got the factory diagram and compared the two. It was a really simple job. Took about one evening after work. The motorcycle seems to run fine with this setup.

 

Just to be sure everything's cool ... test the charging output.

Look for a little above 14 Volts at the battery when you are making slightly over 2,500 rpm's.

 

ok i got the bike to turn over now it will turn over for a little while then just stop i don't know what the problem is if i had the wrong battery in the bike would that cause the problem or maye a ground please help i am in nc if any one is near me i will pay them to come fix the bike i just want to ride

 

Where in NC are you?

 

i live in lexington just south of winston