Minimal wiring

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.