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Minimal wiring

Discussion in 'XJ Technical Chat' started by saftie, Jul 8, 2015.

  1. saftie

    saftie Well-Known Member Premium Member

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    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
     
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  2. Polock

    Polock Well-Known Member

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    [​IMG]
    [​IMG]
    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.
     
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  3. saftie

    saftie Well-Known Member Premium Member

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    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.
     
  4. Polock

    Polock Well-Known Member

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    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
     
  5. saftie

    saftie Well-Known Member Premium Member

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    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
     
    Last edited: Jul 9, 2015
  6. saftie

    saftie Well-Known Member Premium Member

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

    [​IMG]

    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?

    [​IMG]
     
  7. saftie

    saftie Well-Known Member Premium Member

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  8. saftie

    saftie Well-Known Member Premium Member

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    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.
     
    Last edited: Jul 12, 2015
  9. Rooster53

    Rooster53 Well-Known Member Premium Member

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    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.
     
  10. saftie

    saftie Well-Known Member Premium Member

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    Hmm, if the blue one is the neutral, what is the white bullet then?
     
  11. Rooster53

    Rooster53 Well-Known Member Premium Member

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    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.
     
  12. saftie

    saftie Well-Known Member Premium Member

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    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.
     
  13. Polock

    Polock Well-Known Member

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    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.
     
  14. saftie

    saftie Well-Known Member Premium Member

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    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
     
  15. jayme

    jayme New Member

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    20150712_203142.jpg
    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
     
  16. saftie

    saftie Well-Known Member Premium Member

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    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.
     
  17. jayme

    jayme New Member

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    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......
     
  18. saftie

    saftie Well-Known Member Premium Member

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    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.
     
  19. Polock

    Polock Well-Known Member

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

    jayme New Member

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    thanks Polock... 1 down 3 to go
     

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