XJ PARTS CATALOG, SECTION D: ELECTRICAL SYSTEM

SECTION D:

ELECTRICAL SYSTEM:

--Electrical System Overview.


ELECTRICAL SYSTEM OVERVIEW:

Electrical problems can be terribly difficult to diagnose properly. Electrical and fuel-related problems manifest themselves in the same ways: hard starting, mis-firing, poor performance, back-firing, etc.

Although the electrical systems on XJ bikes are fairly durable, there are a number of known, common problem areas on these bikes, which are compounded by the fact that these bikes are 25+ years old.

The fusebox is the most critical area: the stock one may have been adequate in 1981, but it's now old, outdated, and ready for the dust-bin of history. We carry replacement ATC-style fuseboxes and in-line fuse holders which allow you to easily upgrade your original.

The generator brushes wear down over time, change their electrical characteristics as they age, and need periodic replacement. They are available as complete brushes with holder assemblies, or brushes only. By the way, in a technical sense, your bike is really equipped with an Alternator, not a Generator (as Yamaha calls it), since the output of that electrical-generating device is an alternating (AC) electrical current, which is then rectified into a direct (DC) current via---you guessed it---the rectifier section of your Regulator box......

Anyway: finally, in a general electrical system sense, the wiring harness on your bike is getting old---and like most vehicle wiring harnesses from this era, they aren't (and never were) the most robust things ever made. Corrosion, weak connectors, and other assorted issues will cause you all sorts of headaches and the agony of electrical troubleshooting nightmares if not addressed and remedied.

An exceptional write-up on the electrical system on XJ-series bikes---the good, the bad, and the ugly---can be found at:

http://web.archive.org/web/20071214...ies.com/MotorCity/Speedway/7795/xjfaqbig.html

I highly recommend that you visit that site and PRINT OUT the FAQ (you never know when a web page might disappear from the web), as it is the "Electrical Bible" for XJ owners!


And understanding the importance of (and how to measure) voltage drops in circuits will go a long way to helping you successfully diagnose and solve electrical problems on your bike:

http://www.motorcycleproject.com/text/volt_drop_test.html

and here’s an easy-to-understand guide to how to perform a voltage-drop test:

http://www.agcoauto.com/content/news/p2_articleid/330

Corrosion on wires (the greenish "skin" that forms on exposed wire) is a real deal-killer when it comes to transmitting electricity properly...............and here's how to make it go away:

www.instructables.com/id/How-to-perfectly-clean-wires-in-minutes

 

SECTION D:

ELECTRICAL SYSTEM TOOLS:

Electrical System Tools:


et1) Aftermarket electrical test MULTIMETERS, the most useful tool you'll ever own for working on electrical systems. High quality test instruments make your life easier, and give you the accurate measurements needed to diagnose and track down electrical system issues.

http://nadp.sws.uiuc.edu/cal/PDF/MulltimeterUse.pdf

https://learn.sparkfun.com/tutorials/how-to-use-a-multimeter?_ga=1.238289411.262114863.1436923213

http://www.masonmonitoring.com/pdf/support/UsingMultimeter.pdf

https://learn.sparkfun.com/tutorials/how-to-read-a-schematic

http://www.autoshop101.com/forms/elec12.pdf


HCP7135 Aftermarket ANALOG (moving needle) MULTIMETER, more accurate than digital meters but a bit less user-friendly. These 6-function meters measure DC voltages (0-100), AC voltages (0-750), Resistance (0-10 megaohms), DC Current (0-10A), and has a small battery testing dial. NOTE: this multimeter does NOT have the capability to perform diode-checking, which can be a useful function when working on these bikes (although, to be honest, a diode failure is a rare event).
$ 89.95


HCP7136 Aftermarket DIGITAL (numerical LCD display) MULTIMETER, less accurate than analog meters but a bit more user-friendly. This 5-function meters measure DC voltages (0-1000), AC voltages (0-700), Resistance (0-2 megaohms), DC Current (0-10A), and Diode Checking. NOTE: this multimeter DOES have the capability to perform diode-checking, which can be a useful function when working on these bikes (although, to be honest, a diode failure is a rare event). Accuracy: DC voltage +/- 0.7%, AC voltage +/- 1.2%, DC current +/- 1%, Resistance +/-1%.
$ 89.95



HCP10589 Aftermarket TIMING LIGHT, inductive pickup 12V powered stroboscopic timing light is used to check the proper functioning of your ignition system at the pick-up coils. Alligator clips for easy power hook-up to the battery, and a clamp-over inductive feed clips over the #1 plug wire. Super-bright xenon-bulb makes daytime use possible.
$ 49.95



Battery Tools, Testers, Chargers, and Hardware:

HCP10448 Aftermarket battery testing HYDROMETER. This is a real hydrometer, not the cheapo 4-dollar special you usually see at the auto parts store. It measure the specific gravity of the electrolytic fluid, which is the proper way to test its condition. Those little "floating balls" testers are barely worth the plastic that they're made of! This professional hydrometer gives you temperature-adjusted specific gravity readings, which is the only accurate method of measurement. And yes, you can use these on your car or tractor or boat battery, too........
$ 18.95

HCP10542 Aftermarket battery testing MINI-HYDROMETER. This is a cheapy, "floating ball" style hydrometer, but it's small size makes it easier to use on motorcycle batteries. It's better than not having one at all! And yes, you can use these on your car or tractor or boat battery, too........
$ 14.95




fbc3) Aftermarket automatic BATTERY CHARGERS. A fully automatic battery charger is the best type to use to provide "trickle charge" to deep-cycle batteries, as it prevents the overcharge conditions that dramatically reduce the life of a battery.

HCP9962 Aftermarket automatic BATTERY CHARGER, standard bench-top style. Features that a 1.5A charger rate can be used to re-charge a dead battery quickly or maintain a trickle-charge for batteries that see infrequent use. Automatically changes from full-charge to float-mode monitoring for the extended battery life and no worries about over-charging. Reverse-hookup protection, LED power-on/charging/charged indicator lights, CSA-certified, and comes with both 50A standard spring clamps or the easy-to-use permanent plug-in connector to permanently attach a charging "pigtail" connector to the battery for instant access. Can be safely used on conventional and AGM style batteries; not recommended for gel-cell batteries.
$ 79.95



HCP28172 Aftermarket fully automatic BATTERY MAINTAINER-CHARGER. This compact wall-transformer style 6V and 12V charger features the latest solid-state, intelligent technology that allows quick, safe, and efficient charging of all battery types: conventional lead acid, maintenance-free lead acid, marine deep-cycle, AGM, gel-cell, and even lithium-ion. Features include: will safely charge even a fully dead battery (one that reads 0 volts), an automatic “de-sulphation” mode that can rescue and extend the life of older batteries, a thermal compensation sensor to prevent under- or over-charging, short-circuit protection, open-circuit protection, over-heat protection, over-charge protection, reverse-hookup protection, and spark protection. Can be hooked directly to the battery terminals with included ring terminals (a water-proof disconnect port is built into the 9-foot long lead wires), or you can use it with the included thin, “needle-nose” style clamps. Automatically changes from full-charge to float-mode monitoring for extended battery life and no worries about over-charging…..you can actually leave this charger hooked up to your battery 24/7 for as long as you want (like, all winter long……..) without risking battery damage (in fact, for all conventional lead-acid batteries, you should attempt to maintain it at 100% charge to maximize the battery life). Works on 110-240V AC current, 1-amp (max.15W) charging current, water-proof housing, 3-year warranty. This is most affordable and best “home-use” battery charger on the market/
$ 49.95

HCP28173 Aftermarket fully automatic BATTERY SUPER-CHARGER, all the same features as the HCP28172 above, but this charger feature more power output (2A, max. 30W charging current) and is a “mini-tabletop” design…..about 5.5” x 2.5”….no bigger than a typical computer mouse!
$ 79.95


HCP10449 Aftermarket automatic BATTERY CHARGER, compact wall-transformer style. Features that a 1.3A "pulse-mode" charger that can be used to re-charge a dead battery or maintain a trickle-charge for batteries that see infrequent use. Automatically changes from full-charge to float-mode monitoring for the extended battery life and no worries about over-charging. Comes with both alligator clips or the easy-to-use permanent plug-in connector to permanently attach a charging "pigtail" connector to the battery for instant access. Can be safely used on conventional and AGM style batteries; not recommended for gel-cell batteries.
$ 89.95

HCP10451 Aftermarket automatic BATTERY MAINTENANCE CHARGER, compact wall-transformer style. Features that a 800ma (0.8A) charger rate, perfect for maintaining a trickle-charge for batteries that see infrequent use. Automatically changes from full-charge to float-mode monitoring for the extended battery life and no worries about over-charging. Reverse-hookup and short-circuit protection, LED power-on/charging/charged indicator lights, waterproof, and comes with both alligator clips or the easy-to-use permanent plug-in connector to permanently attach a charging "pigtail" connector to the battery for instant access. No bigger than a typical computer "mouse"! Can be safely used on conventional and AGM style batteries; not recommended for gel-cell batteries.
$ 69.95

HCP10452 Aftermarket battery charger EXTENSION CABLE, 12-foot length. Don't want to bring your bike over to your charger? Then this set of 12-foot long charger-to-battery leads extender cable allows you to leave the battery charger close to a wall outlet, and extend the power leads to wherever your bike is located! Quick-connect feature allows plug-and-play installation with all of the above chargers. Very convenient.
$ 24.95




et3) Aftermarket motorcycle-sized BATTERY JUMPER CABLES. Small sized end clips more easily reach into the cramped areas where your battery lives, making it somewhat easier to jump-start a dead bike. NOTE: NEVER attach jumper cables to your battery unless your ignition key is OFF......or your risk frying a lot of expensive electrical components!

HCP1608 Aftermarket 5-foot long standard duty JUMPER CABLES, with alligator clip ends.
$ 37.95




Electrical System Chemicals and Supplies:

NOTE: it’s important to understand the difference between the two types of greases used with electrical connectors. Di-electric grease acts as an electrical insulator: it does not allow current to flow through it easily, and is basically used to “waterproof” a connector assembly. Although it is an insulator, the act of engaging two electrical connectors together (i.e. pushing a male connector into a female connector) will push away the grease on the metal-to-metal contact portion of the terminals, so those remain electrically conductive (good) while also insulating all the other surfaces against moisture and oxygen intrusion (very good). This insulating property of di-electric grease makes it great for use in connector shells, etc. as terminal corrosion is one of the greatest contributors to electrical system problems in vehicles (especially older ones)……this is why most modern vehicles use “sealed” connector shells (the most popular is the Delphi Automotive brand called “weather pack” or “weatherpak”) to keep oxygen and moisture away from the metal terminals. Although you can retrofit these style connectors to older harnesses, it takes a LOT of time, money, and effort to do so.

Now, contrast the insulating properties of di-electric grease to the electrically conductive properties of Conductive Grease, which, as its name implies, the grease itself (which contains many fine carbon particles) conducts electricity. Of course, being a “grease”, it too will also protect and insulate a terminal coated with it from moisture, corrosion, etc…..same as di-electric grease. But…it’s conductive, and if the terminal it coats is electrically “hot”, so is the grease (i.e. touching the grease alone will shock you!).

So a conductive grease is great when you need protection plus current flow……ideal for frame (or battery) grounds to the frame, etc. You could---if you are totally anally-retentive---coat (for instance) a battery post internally with conductive grease, and then cover all of that with di-electric grease.

So, think of these grease as two different electrical system “tools”, and use accordingly.


et2) Aftermarket electrical connector DI-ELECTRIC GREASE coats, insulates, and protects metal terminal connectors from exposure to air, thus preventing oxidation, the killer of electrical systems. Smear some of this goo on each and every one of your electrical connectors (after you've cleaned them with some sandpaper or terminal cleaner) and you'll be doing yourself a big favor!

HCP14059 Aftermarket packet of DI-ELECTRIC GREASE, single use 2-gram packet, enough to do a few light bulbs, terminals, etc.
$ 4.95

HCP7528 Aftermarket tube of DI-ELECTRIC GREASE, big 3-ounce squeeze tube.
$ 21.95


NOTE: the following 2 product(s) can only be shipped via ground transport (which thus eliminates the postal Priority Mail, postal Express Mail, or private carrier Expedited levels of service for this item) and cannot (and will not----don't even ask!) be shipped outside of the continental USA. Additionally, there may be a per-package weight or quantity restriction, and thus multiple-unit orders of this product may have to be shipped in separate packages and will incur additional shipping charges.

HCP20940 Aftermarket tube of DI-ELECTRIC GREASE, 3.3-ounce aerosol can of marine grade grease, with adjustable nozzle size to tailor the grease output bead size to minimize slop and waste and making application much easier. 1-2 cans will do all connectors on an entire bike harness.
$ 24.95



et14) Aftermarket electrical connector CONDUCTIVE GREASE coats and protects metal terminal connectors from exposure to air, thus preventing oxidation, the killer of electrical systems. Unlike the di-electric grease listed above, which is an insulator (non-conductive), this carbon-based grease is electrically conductive and has multiple applications (such as battery terminal posts (internally), frame grounds, etc.).

HCP27923 Aftermarket packet of CONDUCTIVE GREASE, single use 2-gram packet, enough to do a few light bulbs, terminals, etc. Even tiny amounts (that you can barely see) will create minimal electrical resistance, so be careful with this stuff around capacitors and such. It gets everywhere, will stain your hands and clothing and take three days to wash off, and smells like some of the worst goop you've ever smelled. Use a toothpick for application. Don't eat it. Wear gloves. 2-gram pouch goes a long way.
$ 6.95



cps2) Aftermarket high-quality CROCUS CLOTH. Unlike sandpaper or emery paper, crocus cloth is a super-fine, cloth-backed soft abrasive that doesn’t “shed” particles during use, and is just the thing for burnishing and polishing of copper electrical contact, like the alternator rotor and starter motor commutators. Sold in a 2” wide x 1-foot long strip, enough for polishing many a commutator or contact.

HCP21378 Aftermarket strip of CROCUS CLOTH, measures 12” x 2”. Each:
$ 4.95




NOTE: the following 3 product(s) can only be shipped via ground transport (which thus eliminates the postal Priority Mail, postal Express Mail, or private carrier Expedited levels of service for this item) and cannot (and will not----don't even ask!) be shipped outside of the continental USA. Additionally, there may be a per-package weight or quantity restriction, and thus multiple-unit orders of this product may have to be shipped in separate packages and will incur additional shipping charges.

HCP10493 Aftermarket battery post TERMINAL SEALER helps keep corrosion from forming on the battery terminals. Fast drying and leaves no residue. Comes in a 6-ounce aerosol can.
$ 12.95

HCP9762 Aftermarket miracle-goo black LIQUID ELECTRICAL TAPE is easier to use than traditional tape products, especially in close-in locations. Great for sealing crimped wire terminal ends to the wire and serves as a good alternative or supplement to shrink tubing. Just brush it on and let it dry! Comes in a 4-ounces brush-top can.
$ 12.95

HCP10508 Aftermarket electrical CONTACT CLEANER is a good general purpose cleaner and de-greaser. Will not harm plastic terminal connector blocks. Fast drying and leaves no residue. Comes in a 16-ounce aerosol can.
$ 14.95




HCP12923 Aftermarket harness bundle VINYL ELECTRICAL TAPE WRAP, black, 20-foot roll.
$ 8.95

HCP13134 Aftermarket harness bundle VINYL ELECTRICAL TAPE WRAP, black, 66-foot roll, almost enough to do one complete harness.
$ 16.95

Additionally, most harnesses had a few short turns of COLORED VINYL ELECTRICAL TAPE WRAP to provide visual identification of "what connector goes where?" during harness assembly and installation. Always located just by the connector shell, about 3-4 turns of this tape was used to both tape off any vinyl sleeve and to properly identify what the connector plugged into. Used primarily at the TCI connector (from the pick-up coils) and at the various small "cube" style relays (headlight relays, sidestand safety switch relays, etc.). Since all of these harness connector shells are the same style and type (4-position, horizontally oriented 2-over-2), this small tape wrap served as a way of indicating which of these many identical connectors went to which component.

HCP13130 Aftermarket harness bundle YELLOW VINYL ELECTRICAL TAPE WRAP, 20-foot roll. Used by the pick-up coil harness connector (at the TCI) on XJ700-X and XJ750-X models, and at the headlight relay connector on all XJ550 models, all XJ650 (except Turbo) models, and all XJ750 Seca models.
$ 7.95

HCP13131 Aftermarket harness bundle RED VINYL ELECTRICAL TAPE WRAP, 20-foot roll. Used by the pick-up coil harness connector (at the TCI) on 1982-83 XJ650 Maxim models, all '81-83 XJ750 models, and all XJ700 non-X models, and at the fuel pump relay connector on all XJ650 Turbo models.
$ 7.95

HCP13132 Aftermarket harness bundle BLUE VINYL ELECTRICAL TAPE WRAP, 20-foot roll. Used by the pick-up coil harness connector (at the TCI) on all XJ550 models, at the emergency stop switch relay connector on all XJ650 Turbo models, and for the sidestand safety switch relay connector on all XJ550 models, all '82-83 XJ650 models, all XJ750 models, XJ900RK and XJ1100 models.
$ 7.95

HCP13133 Aftermarket harness bundle GREEN VINYL ELECTRICAL TAPE WRAP, 20-foot roll. Used by the pick-up coil harness connector (at the TCI) on all XJ650RJ Seca and XJ1100 models.
$ 7.95





et26) Aftermarket electrical device SWITCH LUBRICANT is a specially formulated, electrically non-conductive penetrating lube that is recommended on control switch turn signal contacts and headlight switching contacts. 10-gram squeeze tube has applicator tip for precision use.

HCP14066 Aftermarket tube of electrical SWITCH LUBRICANT.
$ 16.95



et27) Aftermarket electrical INSTRUMENT OIL is a highly refined light oil for use on speedometer heads, tachometers, gauges, mechanical clocks, etc. Will not congeal even at 50-below-zero! Extra-slow rate of evaporation makes sure that it provides lubrication for a long, long time. 1-ounce pen has an applicator needle tip for precision use.

HCP20852 Aftermarket hi-performance INSTRUMENT OIL, comes in a handy applicator pen. Oil-based triple-processed lubricant eliminates contaminants that would cause gumming or corrosion product is what we use and recommend for freeing stuck fork tube cap bolts[/b][/color].
$ 37.95



HCP10540 Aftermarket acid-neutralizing BATTERY MAT, thin felt mat with pressure-treated with a battery-acid neutralizing chemical. Easily placed directly under the battery, it prevents any spills or discharge from the battery from doing damage to your paint, frame, etc. Trim to fit your battery box with a sharp knife or a pair of scissors. For all XJ550, XJ650, XJ700, XJ750, and XJ900RK models.
$ 9.95

HCP10541 Aftermarket acid-neutralizing BATTERY MAT, thin felt mat with pressure-treated with a battery-acid neutralizing chemical. Easily placed directly under the battery, it prevents any spills or discharge from the battery from doing damage to your paint, frame, etc. Trim to fit your battery tray with a sharp knife or a pair of scissors. For all XJ1100 models.
$ 13.95



HCP10580 Aftermarket acid-neutralizing BATTERY TERMINAL PROTECTORS, thin, round felt mat circles are pressure-treated with a battery-acid neutralizing chemical. Placed under the battery terminal posts, they help prevents any spills or discharge from the battery from creating terminal corrosion. Trim and size to fit your battery posts with a sharp knife or a pair of scissors. Order 1 per terminal, 2 per battery. Each:
$ 3.95

 

SECTION D:

ELECTRICAL SYSTEM:

--Electrical System Wiring: Fuseboxes



WIRING SYSTEM:

FUSEBOXES, FUSEHOLDERS, AND FUSES:

COMMENTS: your stock fusebox was marginal, at best, and that was 20+ years ago. Replacing it with a modern style fuse panel or in-line fuse holders such as the styles listed below in the Replacement Fuseboxes section will prevent frustrating, expensive, and potentially dangerous electrical system problems for years to come.


The following models used a fusebox utilizing four "glass tube" AGC fuses with one 20A main fuse, and three 10A fuses for the ignition, turn signal, and headlight circuits: all XJ550 models, all XJ650 models, 1983 XJ750 Maxim and XJ750 Midnight Maxim models, and the main fusebox on XJ1100 models.

These models used a fusebox utilizing four "glass tube" AGC fuses that contained one 30A main fuse, and three 10A fuses for the ignition, turn signal, and headlight circuits: 1982 XJ750 Maxim model, all XJ750 Seca models, and the XJ900RK Seca.

In addition, the following models used a separate single "glass tube" 5A AGC fuse, within its own small in-line holder, for the computerized gauge cluster: all XJ650 Turbo models, 1982 XJ750 Maxim, and all XJ750 Seca models. This fuseholder is certainly a candidate for updating with the 10A ATO style in-line fuse holder HCP7122 listed below.


XJ700 models used two separate fuse panels: one that contained the four secondary circuits, including two 10A fuses, and two 15A fuses, which is located within the instrument warning lights panel; and a separate 30A main circuit in-line fuse holder was located under the seat. These bikes used the later push-in style ATC fuses in the dash fuse panel from the factory; the 30A main circuit fuses were still the older "glass tube" AGC style fuse, and that is certainly a candidate for updating with the 30A ATC style in-line fuse holder HCP6833 or HCP16777 listed below.

1978-79 XS1100 models use a single fusebox utilizing four "glass tube" AGC fuses with one 30A main fuse, one 20A signals circuit fuse, and two 10A fuses for the ignition and headlight circuits. These models also used a small “accessory terminal” which held a single 10A fuse, and which allowed the for easy installation of any accessory circuit that the owner which to create (or, for use with the factory optional front fairing).

XJ1100 an 1980-81 XS1100 models also used two separate fuse panels: one that contained four secondary circuits, which is located behind the right side frame panel; along with a 30A main fuse in a separate in-line fuse holder that uses the old glass-style fuse, and both are certainly candidates for updating with the ATC style fusebox and fuseholder. These models also used a small “accessory terminal” which held a single 10A fuse, and which allowed the for easy installation of any accessory circuit that the owner which to create (or, for use with the factory optional front fairing).



ORIGINAL STYLE "GLASS-TUBE" FUSEBOXES:

If you're doing a "museum-quality" restoration, where every detail has to be period-correct, then you'll want to consider using an original reproduction FUSEBOX that is faithful to the original design, style, and appearance, right down to the included glass fuses!

These fuseboxes come with an already-installed 8-position plastic terminal block on the fusebox lead wires----and matching connector block and terminals for the harness side wires----which makes installation and maintenance tasks much easier. The entire fusebox can be easily removed from the bike, (or the entire airbox filter lid can be removed, on models that have the fuse panel screwed to the lid) since it's on its own little stub-harness now! If the original direct-wired method is desired, you can always remove the connector block, and tie into your original harness wires, using the butt connectors listed below. You will need 6 of the 18-22 gauge connectors and 2 of the 14-16 gauge connectors in order to convert these fuseboxes to a direct-wire application.


HCP11182 Aftermarket ORIGINAL STYLE FUSEBOX, with installed stub harness and connector block, proper orientation for all XJ550, all XJ650 (except Turbo), and all 1983 XJ750 Maxim and Midnight Maxim models. Comes with original glass fuses (1 x 20A and 3 x 10A).
$ 59.95

HCP10444 Aftermarket ORIGINAL STYLE FUSEBOX, with installed stub harness and connector block, proper orientation for all 1984-85 FJ600, XJ650 Turbo, and XJ1100 models. Comes with original glass fuses (1 x 20A and 3 x 10A).
$ 52.95

HCP24652 Aftermarket ORIGINAL STYLE FUSEBOX, with installed stub harness and connector block, proper orientation for 1982 XJ750 Maxim, all 1981-83 XJ750 Seca and XJ750 Euro models, and all XJ900 models. Comes with original glass fuses (1 x 30A and 3 x 10A).
$ 59.95

HCP24654 Aftermarket ORIGINAL STYLE FUSEBOX, with installed stub harness and connector block, proper orientation for 1984 XJ750RL Seca models. Comes with original glass fuses (1 x 30A, 1 x 20A, and 2 x 10A).
$ 59.95



HCP13045 Aftermarket wire-joining CRIMPABLE, HEAT-SHRINK INSULATED, SOLDER-SLEEVE BUTT CONNECTOR, for wires that are both 18-22 gauge. Each:
$ 1.95

HCP13045SET10 Aftermarket wire-joining CRIMPABLE, HEAT-SHRINK INSULATED, SOLDER-SLEEVE BUTT CONNECTORS, for wires that are both 18-22 gauge. Set of 10:
$ 16.95



HCP13046 Aftermarket wire-joining CRIMPABLE, HEAT-SHRINK INSULATED, SOLDER-SLEEVE BUTT CONNECTOR, for wires that are both 14-16 gauge. Each:
$ 1.95

HCP13046SET10 Aftermarket wire-joining CRIMPABLE, HEAT-SHRINK INSULATED, SOLDER-SLEEVE BUTT CONNECTORS, for wires that are both 14-16 gauge. Set of 10:
$ 16.95



HCP14606 OEM original fusebox FUSEHOLDER CLIP TERMINAL, fits into stock factory fuseboxes, crimp-on, open-barrel style tin-plated brass terminals fits all stock XJ-series fuseboxes that use glass fuses. Use 2 per circuit, a total of 8 per fusebox. Each:
$ 10.95

HCP24811 Aftermarket fusebox FUSEHOLDER CLIP TERMINAL, fits into stock factory fuseboxes, crimp-on, open-barrel style brass terminals fits all stock XJ-series fuseboxes that use glass fuses. Use 2 per circuit, a total of 8 per fusebox. Each:
$ 6.95


HCP23089 Aftermarket original-style fusebox FUSEHOLDER CLIP TERMINALS WITH WIRES, fits into stock factory fuseboxes. This set of terminals with attached wire leads will perfectly replace your commonly broken original fuseholder clips. This set of 2 clips with attached wire leads are for the MAIN CIRCUIT and has the proper 14-gauge solid red wire leads attached. Fuse not included. Fits all XJ models except XJ700, XJ750-X, and XJ1100 models. Wire leads will need to be spliced, soldered, or otherwise attached to your original wire leads (such as with the butt connectors listed above). Each set:
$ 21.95

HCP23090 Aftermarket original-style fusebox FUSEHOLDER CLIP TERMINALS WITH WIRES, fits into stock factory fuseboxes. This set of terminals with attached wire leads will perfectly replace your commonly broken original fuseholder clips. This set of 2 clips with attached wire leads are for the SIGNALS CIRCUIT and has the proper 18-gauge solid brown wire leads attached. Fuse not included. Fits all XJ models except XJ700, XJ750-X, and XJ1100 models. Wire leads will need to be spliced, soldered, or otherwise attached to your original wire leads (such as with the butt connectors listed above). Each set:
$ 21.95

HCP23091 Aftermarket original-style fusebox FUSEHOLDER CLIP TERMINALS WITH WIRES, fits into stock factory fuseboxes. This set of terminals with attached wire leads will perfectly replace your commonly broken original fuseholder clips. This set of 2 clips with attached wire leads are for the IGNITION CIRCUIT and has the proper 18-gauge red with white tracer stripe wire leads attached. Fuse not included. Fits all XJ models except XJ700, XJ750-X, and XJ1100 models. Wire leads will need to be spliced, soldered, or otherwise attached to your original wire leads (such as with the butt connectors listed above). NOTE: some models used solid brown wires for the ignition circuit, in which case you can either use these (which we recommend doing), or, you can use the HCP23090 set above. Each set:
$ 21.95

HCP23092 Aftermarket original-style fusebox FUSEHOLDER CLIP TERMINALS WITH WIRES, fits into stock factory fuseboxes. This set of terminals with attached wire leads will perfectly replace your commonly broken original fuseholder clips. This set of 2 clips with attached wire leads are for the HEADLIGHT CIRCUIT and has the proper 16-gauge red with yellow tracer stripe wire leads attached. Fuse not included. Fits all XJ models except XJ700, XJ750-X, and XJ1100 models. Wire leads will need to be spliced, soldered, or otherwise attached to your original wire leads (such as with the butt connectors listed above). NOTE: some models used solid brown wires for the headlight circuit, in which case you can either use these (which we recommend doing), or, you can use the HCP23090 set above. Each set:
$ 21.95



rf3) Aftermarket replacement GLASS AGC FUSES for use with the stock original fuseboxes or fuse holders.

NOTE: the following replacement fuses are slightly longer than the stock, original fuses (you still have those in there????!) but the additional length will not cause any problems with use.


HCP7144 Aftermarket glass tube 5-AMP AGC FUSE, each:
$ 0.45

HCP7144SET5 Aftermarket glass tube 5-AMP AGC FUSES, set of 5:
$ 1.95


HCP1276 Aftermarket glass tube 10-AMP AGC FUSE, each:
$ 0.45

HCP1276SET5 Aftermarket glass tube 10-AMP AGC FUSES, set of 5:
$ 1.95


HCP7145 Aftermarket glass tube 15-AMP AGC FUSE, each:
$ 0.45

HCP7145SET5 Aftermarket glass tube 15-AMP AGC FUSES, set of 5:
$ 1.95


HCP1275 Aftermarket glass tube 20-AMP AGC FUSE, each:
$ 0.45

HCP1275SET5 Aftermarket glass tube 20-AMP AGC FUSES, set of 5:
$ 1.95


HCP7143 Aftermarket glass tube 30-AMP AGC FUSE, each:
$ 0.45

HCP7143SET5 Aftermarket glass tube 30-AMP AGC FUSES, set of 5:
$ 1.95




The following fuses are the original “short” style fuses, and will certainly get your bike to the 11th level! Note that these fuses are current manufacturer (not 30 year-old fuses!):

HCP23094 Aftermarket glass tube 10-AMP ORIGINAL FUSE, each:
$ 1.95

HCP23095 Aftermarket glass tube 20-AMP ORIGINAL FUSE, each:
$ 1.95

HCP24653 Aftermarket glass tube 30-AMP ORIGINAL FUSE, each:
$ 1.95



Original Fusebox Hardware:

HCP23087 Aftermarket original-style fusebox plastic LID, black plastic snap-on lid fits and appears just like original.
$ 21.95

HCP23088 Aftermarket original-style fusebox plastic BASE, black plastic base accepts the original fuseholder clips just like the original.
$ 18.95


HCP787 OEM original fusebox rubber BOOT, covers the bottom edge of the stock fusebox and acts as an anti-vibration damper. Fits all original XJ-series fuseboxes (except XJ700 models), but was only used originally on XJ650RJ Seca, 1982 XJ650 Turbo, and all XJ750 models. NOTE: you will need to use the HCP2520 screws, the HCP2519 collar, and the HCP306 washers with this boot.
$ 21.95


HCP314 OEM original fusebox-to-filter lid RETAINING SCREW, secures the fusebox to the filter lid on the airbox. Zinc-plated alloy steel, panhead, phillips-drive. Fits all XJ550 models, use 2 per fusebox, each:
$ 3.95

HCP5335 OEM fusebox-to-filter lid RETAINING SCREW, secures the fusebox to the filter lid on the airbox. Black alloy steel, panhead, phillips-drive. Fits all XJ550 models, use 2 per fusebox, each:
$ 8.95

HCP915 Aftermarket fusebox-to-filter lid RETAINING SCREW, secures the fusebox to the filter lid on the airbox. Zinc-plated alloy steel, panhead, phillips-drive. Fits all XJ550 models, use 2 per fusebox, each:
$ 1.95

HCP316 Aftermarket fusebox-to-filter lid RETAINING SCREW, secures the fusebox to the filter lid on the airbox. 18-8 stainless steel, panhead, phillips-drive. Fits all XJ550 models, use 2 per fusebox, each:
$ 2.95

HCP317 Aftermarket fusebox-to-filter lid RETAINING SCREW, secures the fusebox to the filter lid on the airbox. 18-8 stainless steel with a polished button head, hex-drive. Fits all XJ550 models, use 2 per fusebox, each:
$ 2.95

HCP318 Aftermarket fusebox-to-filter lid RETAINING SCREW, secures the fusebox to the filter lid on the airbox. 18-8 stainless steel with a smooth, polished socket head, hex-drive. Fits all XJ550 models, use 2 per fusebox, each:
$ 2.95

HCP320 Aftermarket fusebox-to-filter lid RETAINING SCREW, secures the fusebox to the filter lid on the airbox. Black-oxide coated alloy steel with a ribbed socket head. Fits all XJ550 models, use 2 per fusebox, each:
$ 1.95



HCP2940 OEM original fusebox MOUNTING SCREW, black, phillips-drive, panhead, alloy steel screw. For all 1984-85 FJ600 models, use 2 per fusebox, each:
$ 4.95

HCP2643 Aftermarket original fusebox MOUNTING SCREW, zinc-plated alloy steel, panhead, phillips drive. For all 1984-85 FJ600 models, use 2 per fusebox, each:
$ 1.95

HCP302 Aftermarket original fusebox MOUNTING SCREW, 18-8 stainless steel, panhead, phillips-drive. For all 1984-85 FJ600 models, use 2 per fusebox, each:
$ 2.95

HCP303 Aftermarket original fusebox MOUNTING SCREW, 18-8 stainless-steel, polished button head, hex-drive. For all 1984-85 FJ600 models, use 2 per fusebox, each:
$ 2.95

HCP56 Aftermarket original fusebox MOUNTING SCREW, 18-8 stainless steel, smooth polished socket head, hex-drive. For all 1984-85 FJ600 models, use 2 per fusebox, each:
$ 2.95

HCP58 Aftermarket original fusebox MOUNTING SCREW, black oxide-coated alloy steel, ribbed socket head, hex-drive For all 1984-85 FJ600 models, use 2 per fusebox, each:
$ 1.95



HCP383 OEM original fusebox-to-filter lid RETAINING SCREW, bright zinc-plated alloy steel, secures the fusebox to the filter lid on the airbox. Fits all XJ650 Maxim, Midnight Maxim, and 1982 XJ650 Turbo models, use 2 per fusebox, each:
$ 3.95

HCP21390 Aftermarket original fusebox-to-filter lid RETAINING SCREW, bright 18-8 stainless steel. Secures the fusebox to the filter lid on the airbox. Fits all XJ650 Maxim, Midnight Maxim, and 1982 XJ650 Turbo models, use 2 per fusebox. NOTE: original screws may have had a blunt tip or a sharp, pointed tip. These replacement screws have a pointed tip. Each:
$ 2.95



HCP2520 OEM original fusebox-to-filter lid RETAINING SCREW, bright zinc-plated alloy steel, secures the fusebox to the filter lid on the airbox. Fits all XJ650RJ Seca, 1983 XJ650 Turbo, and all XJ750 models, use 2 per fusebox, each:
$ 3.95

HCP25893 Aftermarket original fusebox-to-filter lid RETAINING SCREW, bright 18-8 stainless steel, secures the fusebox to the filter lid on the airbox. Fits all XJ650RJ Seca, 1983 XJ650 Turbo, and all XJ750 models, use 2 per fusebox, each:
$ 2.95



HCP4168 OEM original fusebox-to-filter lid RETAINING SCREW, bright zinc-plated alloy steel. Secures the fusebox to the filter lid on the airbox. Fits all XJ900RK, RL, N/FN, and F models, use 2 per fusebox, each:
$ 5.95

HCP25892 Aftermarket original fusebox-to-filter lid RETAINING SCREW, bright 18-8 stainless steel. Secures the fusebox to the filter lid on the airbox. Fits all XJ900RK, RL, N/FN, and F models, use 2 per fusebox, each:
$ 3.95



HCP2519 OEM original fusebox-to-filter lid retaining screw COLLAR, hollow metal sleeve used with the HCP2520 screw above. Fits all XJ650RJ Seca, 1983 XJ650 Turbo, and all XJ750 models, use 2 per fusebox, each:
$ 2.95



HCP2173 OEM original fusebox-to-filter lid retaining screw FLAT WASHER, used with the HCP314 screw above. Fits all XJ550 models, use 2 per fusebox, original bright finish, each:
$ 2.95

HCP6642 Aftermarket original fusebox-to-filter lid retaining screw FLAT WASHER, zinc-plated alloy steel with a natural finish, used with the HCP314 screw above. Fits all XJ550 models, use 2 per fusebox, each:
$ 1.95

HCP6643 Aftermarket original fusebox-to-filter lid retaining screw FLAT WASHER, 18-8 stainless steel with a natural finish, used with the HCP314 screw above. Fits all XJ550 models, use 2 per fusebox, each:
$ 2.95

HCP25756 Aftermarket original fusebox-to-filter lid retaining screw FLAT WASHER, 316 stainless steel with a natural finish, used with the HCP314 screw above. Fits all XJ550 models, use 2 per fusebox, each:
$ 3.95

HCP14285 Aftermarket original fusebox-to-filter lid retaining screw FLAT WASHER, black oxide-coated 18-8 stainless steel, used with the HCP314 screw above. Fits all XJ550 models, use 2 per fusebox, each:
$ 2.95

HCP14284 Aftermarket original fusebox-to-filter lid retaining screw FLAT WASHER, black oxide-coated hardened alloy steel, used with the HCP314 screw above. Fits all XJ550 models, use 2 per fusebox, each:
$ 2.95




HCP306 OEM original fusebox-to-filter lid retaining screw FLAT WASHER, bright zinc-plated alloy steel, used with the HCP2520, HCP2940, and HCP4168 screws above. Fits all FJ600, XJ650 models (except 1983 XJ650 Turbo), all XJ750 models, and XJ900RK, RL, and N/FN models. Use 2 per fusebox, each:
$ 2.95

HCP914 Aftermarket fusebox-to-filter lid retaining screw FLAT WASHER, bright zinc-plated alloy steel, used with the HCP2520, HCP2940, and HCP4168 screws above. Fits all FJ600, XJ650 models (except 1983 XJ650 Turbo), all XJ750 models, and XJ900RK, RL, and N/FN models. Use 2 per fusebox, each:
$ 1.95

HCP1353 Aftermarket fusebox-to-filter lid retaining screw FLAT WASHER, bright 18/8 stainless steel, used with the HCP2520, HCP2940, and HCP4168 screws above. Fits all FJ600, XJ650 models (except 1983 XJ650 Turbo), all XJ750 models, and XJ900RK, RL, and N/FN models. Use 2 per fusebox, each:
$ 2.95

HCP65 Aftermarket fusebox-to-filter lid retaining screw FLAT WASHER, black oxide-coated stainless steel, used with the HCP2520, HCP2940, and HCP4168 screws above. Fits all FJ600, XJ650 models (except 1983 XJ650 Turbo), all XJ750 models, and XJ900RK, RL, and N/FN models. Use 2 per fusebox, each:
$ 2.95



HCP55 OEM original fusebox mounting screw LOCK WASHER. For all FJ600 models, use 2 per fusebox, each:
$ 1.95

HCP913 Aftermarket original fusebox mounting screw LOCK WASHER. Zinc-plated alloy steel with a bright finish. For all FJ600 models, use 2 per fusebox, each:
$ 1.75

HCP57 Aftermarket original fusebox mounting screw LOCK WASHER. 18-8 stainless steel with a bright finish. For all FJ600 models, use 2 per fusebox, each:
$ 2.95

HCP59 Aftermarket original fusebox mounting screw LOCK WASHER. Black-oxide coated alloy steel with a dark finish. For all FJ600 models, use 2 per fusebox, each:
$ 1.95




HCP2940 OEM original accessory fuse terminal assembly MOUNTING SCREW, black, phillips-drive, panhead, alloy steel screw. For all XJ1100 and XS1100 models, use 3 per terminal assembly, each:
$ 4.95

HCP2643 Aftermarket original accessory fuse terminal assembly MOUNTING SCREW, zinc-plated alloy steel, panhead, phillips drive. For all XJ1100 and XS1100 models, use 3 per terminal assembly, each:
$ 1.95

HCP302 Aftermarket original accessory fuse terminal assembly MOUNTING SCREW, 18-8 stainless steel, panhead, phillips-drive. For all XJ1100 and XS1100 models, use 3 per terminal assembly, each:
$ 2.95

HCP303 Aftermarket original accessory fuse terminal assembly MOUNTING SCREW, 18-8 stainless-steel, polished button head, hex-drive. For all XJ1100 and XS1100 models, use 3 per terminal assembly, each:
$ 2.95

HCP56 Aftermarket original accessory fuse terminal assembly MOUNTING SCREW, 18-8 stainless steel, smooth polished socket head, hex-drive. For all XJ1100 and XS1100 models, use 3 per terminal assembly, each:
$ 2.95

HCP58 Aftermarket original accessory fuse terminal assembly MOUNTING SCREW, black oxide-coated alloy steel, ribbed socket head, hex-drive. For all XJ1100 and XS1100 models, use 3 per terminal assembly, each:
$ 1.95




HCP306 OEM original accessory fuse terminal assembly retaining screw FLAT WASHER, bright zinc-plated alloy steel, used with the screws above. For all XJ1100 and XS1100 models, use 3 per terminal assembly, each:
$ 2.95

HCP914 Aftermarket original accessory fuse terminal assembly retaining screw FLAT WASHER, bright zinc-plated alloy steel, used with the screws above. For all XJ1100 and XS1100 models, use 3 per terminal assembly, each:
$ 1.95

HCP1353 Aftermarket original accessory fuse terminal assembly retaining screw FLAT WASHER, bright 18/8 stainless steel, used with the screws above. For all XJ1100 and XS1100 models, use 3 per terminal assembly, each:
$ 2.95

HCP65 Aftermarket original accessory fuse terminal assembly retaining screw FLAT WASHER, black oxide-coated stainless steel, used with the screws above. For all XJ1100 and XS1100 models, use 3 per terminal assembly, each:
$ 2.95



HCP55 OEM original accessory fuse terminal assembly retaining screw mounting screw LOCK WASHER. For all XJ1100 and XS1100 models, use 3 per terminal assembly, each:
$ 1.95

HCP913 Aftermarket original accessory fuse terminal assembly retaining screw LOCK WASHER. Zinc-plated alloy steel with a bright finish. For all XJ1100 and XS1100 models, use 3 per terminal assembly, each:
$ 1.75

HCP57 Aftermarket original accessory fuse terminal assembly retaining screw LOCK WASHER. 18-8 stainless steel with a bright finish. For all XJ1100 and XS1100 models, use 3 per terminal assembly, each:
$ 2.95

HCP59 Aftermarket original accessory fuse terminal assembly retaining screw LOCK WASHER. Black-oxide coated alloy steel with a dark finish. For all XJ1100 and XS1100 models, use 3 per terminal assembly, each:
$ 1.95




REPLACEMENT FUSEBOXES AND ACCESSORIES:

Upgrading your electrical system couldn't be simpler with one of our aftermarket style enclosed, waterproof fuse panels.....bringing your bike a long way up to 21st century standards of electrical wiring, and helping to prevent and eliminate annoying, frustrating, and down-right dangerous electrical issues that worn out stock fuseboxes suffer from.

So, if your fusebox (or the remains of it) look anything like this:

http://www.xjbikes.com/forums/index.php?threads/photo-of-new-fusebox-install.14200/#post-121673

or this:

http://xjbikes.com/forums/index.php?threads/fuse-panel-poll-yes-no-will-wont.9277/page-2#post-87015

then it's time to solve a number of problems and potential problems, all at once!


And here is the shocking video that everyone’s talking about, showing the entire install on an XJ650 Maxim model (other models, besides the XJ1100 and XS1100 models, are all basically the same procedure):




FITMENT: the stock Yamaha fusebox is very flat...less than an inch tall. These aftermarket fuseblocks are quite a bit taller, and therefore may present some challenges and the need for some creative engineering to place them properly. In some cases the small "document holder" under the seat may need to be removed. We offer the following tips:

XJ550 models (all): the stock fusebox lays on top of the "tool kit caddy", and the forward "arms" of this caddy hold both the TCI (on the right side) and the fusebox (on the left side). These aftermarket fuseboxes will not fit in the same place as the stock fusebox, as the increased height will cause interference with the bottom of the seat pan. The best fit can be obtained by carefully cutting away a portion of the left tool caddy "arm", so that the replacement fusebox can be attached to the top of the air filter housing. Careful positioning of the fusebox will allow you to remove a minimal amount of the tool caddy arm material, thus retaining the structural strength of that arm. The replacement fusebox should them be retaining to the top of the air filter box via two self-tapping screws, or proper sized bolts and nuts. Here is a good image of what it should look like when you're done:

http://xjbikes.com/forums/index.php?threads/14200

and

http://www.xjbikes.com/forums/threads/how-to-install-an-aftermarket-fuse-box.6350/page-2#post-523114


XJ650 all models (except Turbo) and all 1981-83 XJ750 models: the stock fusebox lays on top of the air cleaner box lid. The replacement fuseblock can go in the same area, but some care must be taken as to positioning to make sure that the bottom of the seat pan does not contact the top of clear cover of the fuseblock. You will have to slightly reposition the fuseblock from the original mounting holes to get everything to line up properly, and you may have to remove the small plastic "document holder" that snaps into the bottom of the seat pan to secure proper clearance. Most clearance issues on these models can be resolved with the use of our FITMENT TEMPLATE and SEAT SPACER KIT listed further below.

Here are the basic steps needed, shown on an XJ650 Maxim model; XJ650RJ Seca and XJ750 Maxim and Seca models are similar. Although this how-to uses a 4-circuit replace fusebox, our 6-circuit panel installs in the same manner:

http://xjbikes.com/forums/index.php?threads/6350

and

http://www.xjbikes.com/forums/threads/fuse-box-replacement.71502/


XJ650 Turbo models: the stock fusebox fits into a flat plastic holder "bar" that fits over the air cleaner box. This holder will no longer be used, and the replacement fusebox will need to be screwed directly to the top of the air cleaner box.


XJ700 and XJ750-X models: these bikes already use the push-in type fuses in a fuse panel (under the gauges) that already comes with ATC style fuses for the auxiliary circuits, and there is no need to upgrade that! Therefore these replacement 6-circuit fuseboxes are not needed on these bikes. However, they also use a 30A main fuse in a separate in-line fuse holder that uses the old glass-style fuse, and that is certainly a candidate for updating with the 30A ATC style in-line fuse holder HCP6833 or HCP16766 listed further below.


XJ900 (and possibly XJ750RL) models: the stock fusebox sits in the "electrical components compartment" caddy under the seat. The replacement fusebox will fit in place of the original fusebox inside this caddy, but you will need to add the HCP12836 spacers to the frame tubes to space the seat pan up slightly (1/8") to prevent interference between the bottom of the seat pan and the top of the fusebox. Here's a great visual how-to:

http://xjbikes.com/forums/index.php?threads/3184


XJ1100 and XS1100 models: these models will require the installation of one of our adapter plates to properly install the enclosed fusebox on these models.



Also available are harness WIRING EXTENSION KITS that contain all the additional color-coded wiring leads, terminals, and connectors needed to make the installation of these aftermarket fuseboxes an even simpler fix!

All fuseboxes and component pieces are available individually, or as COMPLETE FUSEBOX UPGRADE KITS, which will give you everything you need to do it right, the first time!




q) We've developed a number of different COMPLETE FUSEBOX UPGRADE KITS to assist you in performing a professional replacement of the stock 4-circuit fusebox (or whatever other type of hacked wiring mess you inherited). Each kit contains the enclosed fusebox, bottom gasket, mounting screws, circuit ID decal, extension wires set, mounting templates (on some models), and seat spacers kit (on some models). In just a few hours time, you’ll be (electrically-speaking) riding in the modern world again.

All of our fusebox kits require no soldering and minimal electrical knowledge. With the use of our optional HCP17820 POWER JUMPER WIRE, you can easily add power to the two additional circuits in any of our 6-circuit fusebox kits, and have a conversion that looks professional and is done safely and properly.


NOTE: all of the following kits comes with a complete set of vinyl insulated butt connectors which are used to attach the ends of the fusebox wires to the original main harness wires. We also have available a set of un-insulated butt connectors and matching dual-wall heat-shrink tube, which is a good alternative for those who wish a more streamlined, weatherproof method of attaching the wires. See part HCP27207 further below.


XJ550 models:

https://www.facebook.com/VintageYam...383213023074/2004383213023074/?type=3&theater


HCP22570KIT Aftermarket COMPLETE FUSEBOX UPGRADE KIT, with standard (non-glow) push-in ATO fuses. Includes the fusebox, a full set of fuses, gasket, mounting screws, installation template, circuit ID decal, and wiring extensions. Fits all XJ550 models.
$ 59.95

HCP22571KIT Aftermarket COMPLETE FUSEBOX UPGRADE KIT, featuring the glow-when-blown style of push-in ATO fuses. Includes the fusebox, a full set of fuses, gasket, mounting screws, installation template, circuit ID decal, and wiring extensions. Fits all XJ550 models.
$ 64.95



XJ650 models:

HCP22572KIT Aftermarket COMPLETE FUSEBOX UPGRADE KIT, with standard (non-glow) push-in ATO fuses. Includes the fusebox, a full set of fuses, gasket, mounting screws, seat spacers, installation template, circuit ID decal, and wiring extensions. Fits all XJ650 (except Turbo) models. NOTE: XJ650RJ Seca and XJ650 Euro models (with the hinged, “flip-up” style seat) may not require the use of the seat spacers included within this kit.
$ 64.95

HCP22573KIT Aftermarket COMPLETE FUSEBOX UPGRADE KIT, featuring the glow-when-blown style of push-in ATO fuses. Includes the fusebox, a full set of fuses, gasket, mounting screws, seat spacers, installation template, circuit ID decal, and wiring extensions. Fits all XJ650 (except Turbo) models. NOTE: XJ650RJ Seca and XJ650 Euro models (with the hinged, “flip-up” style seat) may not require the use of the seat spacers included within this kit.
$ 69.95



HCP22574KIT Aftermarket COMPLETE FUSEBOX UPGRADE KIT, with standard (non-glow) push-in ATO fuses. Includes the fusebox, a full set of fuses, gasket, mounting screws, circuit ID decal, and wiring extensions. Fits all XJ650 Turbo models. NOTE: can be used on all other XJ650 models but does not include the seat spacers nor the installation template).
$ 59.95

HCP22575KIT Aftermarket COMPLETE FUSEBOX UPGRADE KIT, featuring the glow-when-blown style of push-in ATO fuses. Includes the fusebox, a full set of fuses, gasket, mounting screws, circuit ID decal, and wiring extensions. Fits all XJ650 Turbo models. NOTE: can be used on all other XJ650 models but does not include the seat spacers nor the installation template).
$ 64.95



XJ750 models:

HCP22576KIT Aftermarket COMPLETE FUSEBOX UPGRADE KIT, with standard (non-glow) push-in ATO fuses. Includes the fusebox, a full set of fuses, gasket, mounting screws, seat spacers, installation template, circuit ID decal, and wiring extensions. Fits all 1982 XJ750 Maxim models.
$ 64.95

HCP22577KIT Aftermarket COMPLETE FUSEBOX UPGRADE KIT, featuring the glow-when-blown style of push-in ATO fuses. Includes the fusebox, a full set of fuses, gasket, mounting screws, seat spacers, installation template, circuit ID decal, and wiring extensions. Fits all 1982 XJ750 Maxim models.
$ 69.95


HCP22578KIT Aftermarket COMPLETE FUSEBOX UPGRADE KIT, with standard (non-glow) push-in ATO fuses. Includes the fusebox, a full set of fuses, gasket, mounting screws, seat spacers, installation template, circuit ID decal, and wiring extensions. Fits all 1983-84 XJ750 Maxim and Midnight Maxim models.
$ 64.95

HCP22579KIT Aftermarket COMPLETE FUSEBOX UPGRADE KIT, featuring the glow-when-blown style of push-in ATO fuses. Includes the fusebox, a full set of fuses, gasket, mounting screws, seat spacers, installation template, circuit ID decal, and wiring extensions. Fits all 1983-84 XJ750 Maxim and Midnight Maxim models.
$ 69.95


HCP22580KIT Aftermarket COMPLETE FUSEBOX UPGRADE KIT, with standard (non-glow) push-in ATO fuses. Includes the fusebox, a full set of fuses, gasket, mounting screws, seat spacers, installation template, circuit ID decal, and wiring extensions. Fits all 1981-83 XJ750 Seca and all XJ750 Euro models.
$ 62.95

HCP22581KIT Aftermarket COMPLETE FUSEBOX UPGRADE KIT, featuring the glow-when-blown style of push-in ATO fuses. Includes the fusebox, a full set of fuses, gasket, mounting screws, seat spacers, installation template, circuit ID decal, and wiring extensions. Fits all 1981-83 XJ750 Seca and all XJ750 Euro models.
$ 67.95



XJ900 models:

HCP22582KIT Aftermarket COMPLETE FUSEBOX UPGRADE KIT, with standard (non-glow) push-in ATO fuses. Includes the fusebox, a full set of fuses, gasket, mounting screws, circuit ID decal, and wiring extensions. Fits all XJ900RK, RL, F, N, and FN models.
$ 59.95

HCP22583KIT Aftermarket COMPLETE FUSEBOX UPGRADE KIT, featuring the glow-when-blown style of push-in ATO fuses. Includes the fusebox, a full set of fuses, gasket, mounting screws, circuit ID decal, and wiring extensions. Fits all XJ900RK, RL, F, N, and FN models.
$ 64.95



XJ1100 models:

NOTE: XJ1100 owners actually have three fuse-holding devices to consider (and thus possibly upgrade):

1) the main circuit remote fuseholder, which is enclosed all by its lonesome as an appendage to the main wiring harness, and....

2) the 4-position "accessory circuits" black lastic fusebox, which mounts to the side of the battery box, and….

3) the 1-position "accessory circuit" terminal block, which mounts under the stock 4-position fusebox. Note that we do not have any “upgrade” option for this (rarely used) terminal block.


ALL of the above devices originally use the "old tech" type of AGC (“all glass” or “automotive glass”, depending on who you listen to……..) cylindrical glass fuses. AGC fuses are also sometimes referred to as SFE (“Society of Fuse Engineers”…..yes there is such an organization!) fuses.


We've developed a number of different kits to allow you to replace the stock 4-position accessory circuit fusebox (that's a must!) with a modern 6-circuit fusebox using the modern style ATO "blade" fuses. You then also have the option to choose between leaving the main fuseholder "as is" (remote from the main fusebox, in its own fuseholder), or, leaving it remote but replacing the original AGC fuse and holder with a modern blade-style ATO fuse and fuseholder.......or going fully modern and eliminating the remote main fuseholder entirely and bringing the main fuse circuit "inside" your new upgraded 6-position fusebox (note that this last choice will eliminate one potential "accessory circuit" from your new 6-circuit fusebox, since one of those "accessory circuits" is now populated by the main fuse circuit, which used to be remote from the fusebox).

Our recommendation: replace the stock remote main circuit fuseholder with a modern version (which uses the blade-style ATO fuse) and, of course, replace the original 4-position fusebox with our upgraded 6-circuit, enclosed, ATO fuseholder. This is what we refer to as “OPTION B” below. This arrangement brings your electrical system (as far as fuses are concerned) fully into the modern era.


Also note that the use of any of our replacement accessory-circuit fusebox kits will require you to modify or eliminate the accessory circuit terminal block unit, located on the bottom left "corner" of the stock fusebox mounting plate, as it makes for an incredibly tight fit for the routing of the circuit wires.

All of our fusebox kits require no soldering and minimal electrical knowledge. With the use of our optional HCP18421 mounting plate kit, you can ensure a quick and painless installation process, and have a professional conversion that both properly fits inside the frame side cover and looks factory-installed.

So here are your options; again, we suggest option B as the more useful and suitable for most owners:


OPTION A: If you want to keep the stock, remote MAIN CIRCUIT fuseholder as-is, and just upgrade the original accessory-circuits fusebox, then order either the HCP378BC or the HCP378LF 6-circuit fuesbox kits, the HCP16766 harness extension wires, and the HCP18421 installation kit:

Order either of these fuseboxes:

HCP378BC Aftermarket ENCLOSED 6-CIRCUIT FUSEBOX KIT, comes with a full set of standard style ATO push-in style fuses (4 x 10A, and 2 x 20A), for all XJ550, all XJ650, 1983 XJ750 Maxim and XJ750 Midnight Maxim, and XJ1100 models. NOTE: XJ1100 owners will not be able to install this fusebox without the use of our HCP18421 mounting plate kit.
$ 29.95

HCP378LF Aftermarket ENCLOSED 6-CIRCUIT FUSEBOX KIT, comes with the optional “glow-when-blown” indicator style ATO push-in fuses (4 x 10A, and 2 x 20A), XJ550, all XJ650, 1983 XJ750 Maxim and XJ750 Midnight Maxim, and XJ1100 models. NOTE: XJ1100 owners will not be able to install this fusebox without the use of our HCP18421 mounting plate kit.
$ 34.95

and this:

HCP16766 Aftermarket 6-circuit fusebox HARNESS EXTENSION WIRES KIT. For all XJ1100 and XS1100 models.
$ 29.95

and this, which will make installation a breeze!:

HCP18421 Aftermarket fusebox MOUNTING PLATE KIT, contains a custom designed black steel mounting plate that allows quick and easy installation of the 6-circuit fusebox to your battery tray. Replaces the original stock fusebox mounting plate and retains and moves the turn signal flasher relay "out of harm's way", a necessity when using the larger aftermarket fusebox. Kit contains the mounting bracket, installation hardware, and illustrated instructions.
$ 49.95


NOTE: all of the following kits comes with a complete set of vinyl insulated butt connectors which are used to attach the ends of the fusebox wires to the original main harness wires. We also have available a set of un-insulated butt connectors and matching dual-wall heat-shrink tube, which is a good alternative for those who wish a more streamlined, weatherproof method of attaching the wires. See part HCP27207 further below.


Option “A” Complete Kits:

HCP26987-BC-KIT Aftermarket “Option A” FUSEBOX UPGRADE KIT, gets you everything you’ll need to do install this selection: an enclosed 6-circuit fusebox with standard ATO fuses, a fusebox circuit ID decal, the fusebox mounting plate kit, and fusebox wiring kit. For all XJ1100 models.
$ 84.95

HCP26987-LF-KIT Aftermarket “Option A” FUSEBOX UPGRADE KIT, gets you everything you’ll need to do install this selection: an enclosed 6-circuit fusebox with the optional “glow-when-blown” indicator style ATO fuses, a fusebox circuit ID decal, the fusebox mounting plate kit, and fusebox wiring kit. For all XJ1100 models.
$ 89.95



OPTION B: If you want to keep the MAIN fuseholder external from the accessory-circuits fusebox, but DO want to replace the stock glass-fuse main fuseholder with a later style "blade" fuse holder, AND upgrade the original accessory-circuits fusebox to a later style "blade" fusebox, then order the HCP16777 main fuseholder replacement kit, either the HCP378BC or the HCP378LF accessory-circuits fusebox kit, the HCP16766 harness extension wires kit, and the HCP18421 installation kit :

Order this:

HCP16777 Aftermarket MAIN FUSEHOLDER REPLACEMENT KIT, contains the weatherproof "blade" style HCP6833 main fuse holder with the white plastic connector shell that plugs into your main wiring harness (just like the original main fuseholder does).....no splicing, dicing, or harness chopping required! Includes 2 x 30A blade fuses (1 for use and 1 as a spare). For all XJ1100 and 1980-81 XS1100 models.
$ 29.95

and either of these fuseboxes:

HCP378BC Aftermarket ENCLOSED 6-CIRCUIT FUSEBOX KIT, comes with a full set of standard style ATO push-in style fuses (4 x 10A, and 2 x 20A), for all XJ550, all XJ650, 1983 XJ750 Maxim and XJ750 Midnight Maxim, and XJ1100 models. NOTE: XJ1100 owners will not be able to install this fusebox without the use of our HCP18421 mounting plate kit.
$ 29.95

HCP378LF Aftermarket ENCLOSED 6-CIRCUIT FUSEBOX KIT, comes with the optional “glow-when-blown” indicator style ATO push-in fuses (4 x 10A, and 2 x 20A), XJ550, all XJ650, 1983 XJ750 Maxim and XJ750 Midnight Maxim, and XJ1100 models. NOTE: XJ1100 owners will not be able to install this fusebox without the use of our HCP18421 mounting plate kit.
$ 34.95

and this:

HCP16766 Aftermarket 6-circuit fusebox HARNESS EXTENSION WIRES KIT. For all XJ1100 and XS1100 models.
$ 29.95

and this, which will make installation a breeze!:

HCP18421 Aftermarket fusebox MOUNTING PLATE KIT, contains a custom designed black steel mounting plate that allows quick and easy installation of the 6-circuit fusebox to your battery tray. Replaces the original stock fusebox mounting plate and retains and moves the turn signal flasher relay "out of harm's way", a necessity when using the larger aftermarket fusebox. Kit contains the mounting bracket, installation hardware, and illustrated instructions.
$ 49.95


Option “B” Complete Kits:

HCP26988-BC-KIT Aftermarket “Option B” FUSEBOX UPGRADE KIT, gets you everything you’ll need to do install this selection: an enclosed 6-circuit fusebox with standard ATO fuses, a fusebox circuit ID decal, the fusebox mounting plate kit, the fusebox wiring kit, and the modern-style ATO main circuit remote fuseholder with fuses. For all XJ1100 models.
$ 89.95

HCP26988-LF-KIT Aftermarket “Option B” FUSEBOX UPGRADE KIT, gets you everything you’ll need to do install this selection: an enclosed 6-circuit fusebox with the optional “glow-when-blown” indicator style ATO fuses, a fusebox circuit ID decal, the fusebox mounting plate kit, the fusebox wiring kit, and the modern-style ATO main circuit remote fuseholder with fuses. For all XJ1100 models.
$ 94.95



OPTION C: If you want to bring the main fuse holder circuit "inside" of the upgraded 6-circuit enclosed fusebox, order either the HCP16769BC or the HCP16769LF fusebox kits below and the HCP16766 wiring harness extension wires kit....note that this eliminates the remote main circuit fuseholder entirely, and moves that circuit into one of the enclosed fusebox circuit positions:

Order either of these fusebox and main fuseholder kits:

HCP16769BC Aftermarket enclosed 6-circuit ENCLOSED 6-CIRCUIT FUSEBOX AND MAIN FUSEHOLDER ELIMINATOR KIT, allows for the elimination of the original remote "main circuit" fuseholder and the placement of the 30A main circuit path inside the new fusebox. The adapter wire has the white plastic connector shell that plugs into your main wiring harness just like the original main fuseholder does.....no splicing, dicing, or harness chopping required! Kit includes the enclosed fusebox, the main fuseholder eliminator harness, and a full complement of standard ATO blade type fuses (4 x 10A, 2 x 20A, and 2 x 30A). For all XJ1100 models.
$ 34.95

HCP16769LF Aftermarket ENCLOSED 6-CIRCUIT FUSEBOX AND MAIN FUSEHOLDER ELIMINATOR KIT, allows for the elimination of the original remote "main circuit" fuseholder and the placement of the 30A main circuit path inside the new fusebox. The adapter wire has the white plastic connector shell that plugs into your main wiring harness just like the original main fuseholder does.....no splicing, dicing, or harness chopping required! Kit includes the enclosed fusebox, the main fuseholder eliminator harness, and a full complement of the optional ”glow-when-blown” indicator style ATO blade type fuses (4 x 10A, 2 x 20A, and 2 x 30A). For all XJ1100 models.
$ 37.95

and this:

HCP16766 Aftermarket 6-circuit fusebox HARNESS EXTENSION WIRES KIT. For all XJ1100 and XS1100 models.
$ 29.95

and this, which will make installation a breeze!:

HCP18421 Aftermarket fusebox MOUNTING PLATE KIT, contains a custom designed black steel mounting plate that allows quick and easy installation of the 6-circuit fusebox to your battery tray. Replaces the original stock fusebox mounting plate and retains and moves the turn signal flasher relay "out of harm's way", a necessity when using the larger aftermarket fusebox. Kit contains the mounting bracket, installation hardware, and illustrated instructions.
$ 49.95


Option “C” Complete Kits:

HCP26989-BC-KIT Aftermarket “Option C” FUSEBOX UPGRADE KIT, gets you everything you’ll need to do install this selection: an enclosed 6-circuit fusebox with standard ATO fuses, a fusebox circuit ID decal, the fusebox mounting plate kit, the fusebox wiring kit, and the main fuseholder elimination/re-location harness. For all XJ1100 models.
$ 89.95

HCP26989-LF-KIT Aftermarket “Option C” FUSEBOX UPGRADE KIT, gets you everything you’ll need to do install this selection: an enclosed 6-circuit fusebox with the optional “glow-when-blown” indicator style ATO fuses, a fusebox circuit ID decal, the fusebox mounting plate kit, the fusebox wiring kit, and the main fuseholder elimination/re-location harness. For all XJ1100 models.
$ 99.95




XS1100 models:

NOTE: on all XS1100 models, when replacing the stock 4-circuit fusebox, the turn signal flasher relay (flasher unit), which is located on the fusebox mounting plate, will cause interference with the the larger 6-circuit fusebox which is provided in our kits, and thus the flasher relay must be relocated. A plug-and-play extension harness and relay mounting bracket is included with our kits to make the relocation of the flasher relay a simple, painless, and professional-looking task (note that what we refer to as the “mounting plate” is the stamped metal plate which is attached to the right side of the battery tray structure, and holds the stock 4-circuit plastic fusebox, the 1-position accessory “terminal block”, the signal flasher relay, and the starter solenoid). However, the mounting “tab” for the flasher relay, which is stamped onto this mounting plate, will need to be removed or folded “out of the way”……..all of this is covered in the illustrated instructions included with the fusebox kit.

All kits include at least the following components: the enclosed, 6-circuit fusebox with a full supply of ATO blade fuses, a circuit ID decal, a fusebox mounting adapter plate, attaching hardware, a flasher relay re-location harness and mounting bracket, and full instructions.

All of our fusebox kits require no soldering and minimal electrical knowledge, and the illustrated instructions insure a quick and painless installation process (1-2 hours, depending on your skill level and mood), and will lead to a professional conversion that both properly fits inside the frame side cover and looks factory-installed.


1978-79 XS1100 models:

NOTE: 1978-79 XS100 owners actually have two fuse-holding devices:

1) the 4-position "accessory circuits" black plastic fusebox, which mounts to the side of the battery box, and which can be upgraded to a modern ATO 6-circuit fusebox, and…….

2) a 1-position "accessory circuit" terminal block, which mounts under the stock 4-position fusebox. Note that we do not have any “upgrade” option for this (rarely used) terminal block.

BOTH of the above devices originally use the "old tech" type of AGC (“all glass” or “automotive glass”, depending on who you listen to……..) cylindrical glass fuses. AGC fuses are also sometimes referred to as SFE (“Society of Fuse Engineers”…..yes there is such an organization!) fuses.

NOTE: all of the following kits comes with a complete set of vinyl insulated butt connectors which are used to attach the ends of the fusebox wires to the original main harness wires. We also have available a set of un-insulated butt connectors and matching dual-wall heat-shrink tube, which is a good alternative for those who wish a more streamlined, weatherproof method of attaching the wires. See part HCP27207 further below.



HCP26996BC Aftermarket FUSEBOX UPGRADE KIT, gets you everything you’ll need to do install this upgrade: an enclosed 6-circuit fusebox with standard ATO fuses, a fusebox circuit ID decal, the fusebox mounting plate kit, and the fusebox wiring kit. For all 1978-79 XS1100 models.
$ 94.95

HCP26996LF Aftermarket FUSEBOX UPGRADE KIT, gets you everything you’ll need to do install this upgrade: an enclosed 6-circuit fusebox with optional “glow-when-blown” indicator type ATO fuses, a fusebox circuit ID decal, the fusebox mounting plate kit, and the fusebox wiring kit. For all 1978-79 XS1100 models.
$ 99.95



1980-81 XS1100 models:

NOTE: 1980-81 XS owners actually have three fuse-holding devices to consider (and thus possibly upgrade):

1) the main power circuit remote fuseholder, which is enclosed all by its lonesome as an appendage to the main wiring harness, and....

2) the 4-position "accessory circuits" black plastic fusebox, which mounts to the side of the battery box, and which can be upgraded to a modern blade-style ATO 6-circuit fusebox, and…….

3) a 1-position "accessory circuit" terminal block, which mounts under the stock 4-position fusebox. Note that we do not have any “upgrade” option for this (rarely used) terminal block.

ALL of the above devices originally use the "old tech" type of AGC (“all glass” or “automotive glass”, depending on who you listen to……..) cylindrical glass fuses. AGC fuses are also sometimes referred to as SFE (“Society of Fuse Engineers”…..yes there is such an organization!) fuses.


We've developed a number of different kits to allow you to replace the stock 4-position accessory circuit fusebox (that's a must!) with a modern 6-circuit fusebox using the modern style ATO "blade" fuses. You then also have the option to choose between leaving the main fuseholder "as is" (remote from the main fusebox, in its own fuseholder), or, leaving it remote but replacing the the main fuseholder AGC fuse and holder with a modern blade-style ATO fuse and fuseholder.......or going fully modern and eliminating the remote main fuseholder entirely, and bringing the main fuse circuit "inside" your new upgraded 6-position fusebox (note that this last choice will eliminate one potential "accessory circuit" from your new 6-circuit fusebox, since one of those "accessory circuits" is now populated by the main fuse circuit, which used to be remote from the fusebox).

Our recommendation: replace the stock remote main circuit fuseholder with a modern version (which uses the blade-style ATO fuse) and, of course, replace the original 4-position fusebox with our upgraded 6-circuit, enclosed, ATO fuseholder. This is what we refer to as “OPTION B” below. This arrangement brings your electrical system (as far as fuses are concerned) fully into the modern era.


NOTE: all of the following kits comes with a complete set of vinyl insulated butt connectors which are used to attach the ends of the fusebox wires to the original main harness wires. We also have available a set of un-insulated butt connectors and matching dual-wall heat-shrink tube, which is a good alternative for those who wish a more streamlined, weatherproof method of attaching the wires. See part HCP27207 further below.



OPTION A KITS: If you want to keep the stock, remote MAIN CIRCUIT fuseholder as-is, and just upgrade the original accessory-circuits fusebox, then order either of the fusebox kits below.

HCP26997BC-KIT Aftermarket “Option A” FUSEBOX UPGRADE KIT, gets you everything you’ll need to do install this option: an enclosed 6-circuit fusebox with standard ATO fuses, a fusebox circuit ID decal, the fusebox mounting plate kit, and fusebox wiring kit. For all 1980-81 XS1100 models.
$ 84.95

HCP26997LF-KIT Aftermarket “Option A” FUSEBOX UPGRADE KIT, gets you everything you’ll need to do install this option: an enclosed 6-circuit fusebox with the optional “glow-when-blown” ATO fuses, a fusebox circuit ID decal, the fusebox mounting plate kit, and fusebox wiring kit. For all 1980-81 XS1100 models.
$ 89.95


OPTION B KITS: If you want to keep the MAIN fuseholder external (outside) from the accessory-circuits fusebox, but DO want to replace the stock glass-fuse main fuseholder with a later style "blade" fuse holder, AND upgrade the original accessory-circuits fusebox to a later style "blade" fusebox, then order either of the fusebox kits below.

HCP26998BC-KIT Aftermarket “Option B” FUSEBOX UPGRADE KIT, gets you everything you’ll need to do install this option: an enclosed 6-circuit fusebox with standard ATO fuses, a fusebox circuit ID decal, the fusebox mounting plate kit, the fusebox wiring kit, and the modern-style ATO main circuit remote fuseholder with fuses. For all 1980-81 XS1100 models.
$ 89.95

HCP26998LF-KIT Aftermarket “Option B” FUSEBOX UPGRADE KIT, gets you everything you’ll need to do install this option: an enclosed 6-circuit fusebox with the optional “glow-when-blown” indicator style ATO fuses, a fusebox circuit ID decal, the fusebox mounting plate kit, the fusebox wiring kit, and the modern-style ATO main circuit remote fuseholder with fuses. For all 1980-81 XS1100 models.
$ 94.95


OPTION C KITS: If you want to bring the stock external MAIN fuse holder circuit "inside" of the upgraded 6-circuit enclosed fusebox, order either of the fusebox kits below……note that this eliminates the remote main circuit fuseholder entirely, and moves that main fuse circuit into one of the enclosed fusebox circuit positions:

HCP26999BC-KIT Aftermarket “Option C” FUSEBOX UPGRADE KIT, gets you everything you’ll need to do install this option: an enclosed 6-circuit fusebox with standard ATO fuses, a fusebox circuit ID decal, the fusebox mounting plate kit, the fusebox wiring kit, and the main circuit fuseholder elimination/re-location harness. For all 1980-81 XS1100 models.
$ 89.95

HCP26999LF-KIT Aftermarket “Option C” FUSEBOX UPGRADE KIT, gets you everything you’ll need to do install this option: an enclosed 6-circuit fusebox with the optional “glow-when-blown” indicator style ATO fuses, a fusebox circuit ID decal, the fusebox mounting plate kit, the fusebox wiring kit, and the main circuit fuseholder elimination/re-location harness. For all 1980-81 XS1100 models.
$ 94.95



Individual Fusebox Components:

u177) Aftermarket 6-CIRCUIT ENCLOSED FUSEBOX. This small, weatherproof fusebox is the most popular replacement for the stock glass-tube fusebox and use "modern" type ATO push-in blade style fuses. Includes 6 ATO standard fuses, 2 x 20A or 2 x 30A (depending on your model), and 4 x 10A fuses. Two more circuits than a stock fusebox allows you to add extra circuits for heated grips, cigarette lighter, headlight relays, etc. Size: 4" long x 1-1/8" wide (not including spade terminals) x 1-1/2" tall (including the clear, see-through cover). Note that this is a "side-terminal" design...the male wire terminal spades point outwards (away) from the sides of the fusebox. Rated for 30 amps maximum current per circuit, and 70 amps maximum current draw for the entire box.

NOTE: fuseboxes do not come with mounting screws; you may re-use your original or order new replacements listed further below. Mounting screw locations will differ from original, and it will be necessary to re-locate at least one (and probably both) to get a correct fit. The HCP21390 mounting screw is the shortest, self-tapping screw available, and is the best length to use on all models. The original mounting screws on XJ550 models is slightly larger in diameter than the mounting holes in these replacement fuseboxes, and thus the hole in the fusebox base will need to be enlarged slightly on those models if you re-use the original mounting screws.

HCP21390 Aftermarket original fusebox-to-filter lid RETAINING SCREW, secures the fusebox to the filter lid on the airbox. For use with any of our aftermarket fuseboxes below on all XJ550 - XJ900 models. Use 2 per fusebox, each:
$ 2.95



Individual Fusebox Components:

HCP378 Aftermarket ENCLOSED 6-CIRCUIT FUSEBOX, fusebox base and lid only; no fuses included, can be used on all models except all XJ700 and XJ750-X (water-cooled) bikes. NOTE: XJ1100 owners will not be able to install this fusebox without the use of our HCP18421 mounting plate kit.
$ 24.95

HCP378BC Aftermarket ENCLOSED 6-CIRCUIT FUSEBOX KIT, comes with a full set of standard style ATO push-in style fuses (4 x 10A, and 2 x 20A), for all XJ550, all XJ650, 1983 XJ750 Maxim and XJ750 Midnight Maxim, and XJ1100 models. NOTE: XJ1100 owners will not be able to install this fusebox without the use of our HCP18421 mounting plate kit.
$ 29.95

HCP378LF Aftermarket ENCLOSED 6-CIRCUIT FUSEBOX KIT, comes with the optional “glow-when-blown” indicator style ATO push-in fuses (4 x 10A, and 2 x 20A), XJ550, all XJ650, 1983 XJ750 Maxim and XJ750 Midnight Maxim, and XJ1100 models. NOTE: XJ1100 owners will not be able to install this fusebox without the use of our HCP18421 mounting plate kit.
$ 34.95



HCP7153BC Aftermarket ENCLOSED 6-CIRCUIT FUSEBOX KIT, comes with a full set of standard style ATO push-in style fuses (4 x 10A, and 2 x 30A), for all XJ750 Seca, 1982 XJ750 Maxim, and XJ900RK, RL, N/FN, and F models.
$ 29.95

HCP7153LF Aftermarket ENCLOSED 6-CIRCUIT FUSEBOX KIT, comes with a full set of glow-when-blown indicator style ATO push-in style fuses (4 x 10A, and 2 x 30A), for all XJ750 Seca, 1982 XJ750 Maxim, and XJ900RK, RL, N/FN, and F models.
$ 34.95



HCP10488BC Aftermarket ENCLOSED 6-CIRCUIT FUSEBOX KIT, comes with a full set of standard style ATO push-in style fuses (1 x 30A, 1 x 20A, and 4 x 10A), for all 1984-85 FJ600, 1984 XJ750RL Seca, and all XS1100 models.
$ 29.95

HCP10488LF Aftermarket ENCLOSED 6-CIRCUIT FUSEBOX KIT, comes with a full set of glow-when-blown indicator style ATO push-in style fuses (1 x 30A, 1 x 20A, and 4 x 10A), for all 1984-85 FJ600, 1984 XJ750RL Seca, and all XS1100 models..
$ 34.95




u73) Aftermarket fusebox FITMENT TEMPLATE for the above HCP378xx or HCP7153xx series 6-circuit fuseboxes. These templates show you the proper method of fitting these fuseboxes into the cramped area of the original boxes, with proper placements and alignments for a fool-proof, no-guesswork fit. XJ650 and XJ750 models may also require a separate SEAT SPACER KIT (even with "perfect" fit) in order to prevent rubbing of the bottom of the seat pan against the top of the fusebox lid.

HCP12833 Aftermarket 6-circuit fusebox FITMENT TEMPLATE, for use with all XJ550 models.
$ 9.95

HCP12834 Aftermarket 6-circuit fusebox FITMENT TEMPLATE, for use with all XJ650 (except Turbo) models.
$ 9.95

HCP12835 Aftermarket 6-circuit fusebox FITMENT TEMPLATE, for use with all 1981-83 XJ750 models.
$ 9.95

HCP12836 Aftermarket 6-circuit fusebox SEAT SPACER KIT, for use with all XJ650 Maxim and Midnight Maxim models, all 1981-83 XJ750 models, and XJ900 models. Contains a set of 4 rubber frame tube "spacers" and a spacer mounting location template. NOTE: depending on your weight, airbox adjustment position, and the condition of your seat pan (they tend to "sag" over time), the use of these spacers may or may not be required on individual bikes.
$ 9.95



nnn) Aftermarket CIRCUIT ID DECAL for the above 6-circuit fuseboxes. Printed on a clear adhesive backed long-life decal material, this decal specifies (in white print) the circuit "name" (MAIN, HEAD, TURN, IGN.), the fuse amp rating of each circuit, and the wire lead color code (BLU, RED, R/Y, BRN, R/W) so you can have the same circuit ID info on your replacement fusebox as on your original. Applies to the outside of the clear fusebox cover. The two empty circuit positions are titled "SPARE".

HCP393 Aftermarket fusebox 6-CIRCUIT ID DECAL, with labeling for 20A main fuse and 10A headlight, ignition, and signal circuits, for all XJ550, all XJ650, and 1983 XJ750 Maxim and XJ750 Midnight Maxim models.
$ 12.95

HCP20241 Aftermarket fusebox 6-CIRCUIT ID DECAL, with labeling for 30A main fuse, 20A headlight circuit, and 10A ignition and signal circuits, for all 1984-85 FJ600 models.
$ 12.95

HCP7152 Aftermarket fusebox 6-CIRCUIT ID DECAL, with labeling for 30A main fuse and 10A headlight, ignition, and signal circuits, for all XJ750 Seca, 1982 XJ750 Maxim, and XJ900RK, RL, N/FN, and F models.
$ 12.95

HCP26951 Aftermarket fusebox 6-CIRCUIT ID DECAL, with labeling for 30A main fuse, 10A headlight circuit, 20A signal circuit, and 10A ignition circuit. For all 1978-79 XS1100 models.
$ 12.95

HCP13475 Aftermarket fusebox 6-CIRCUIT ID DECAL, with labeling for 10A taillight fuse, 10A headlight circuit, 20A signal circuit, and 10A ignition circuit. For all XJ1100 and 1980-81 XS1100 models in the stock configuration (with the main fuse circuit remaining external to the fusebox).
$ 12.95

HCP26952 Aftermarket fusebox 6-CIRCUIT ID DECAL, with labeling for 30A main fuse, 10A taillight fuse, 10A headlight circuit, 20A signal circuit, and 10A ignition circuit. For all XJ1100 and all 1980-81 XS1100 models when the main fuse circuit is brought inside the fusebox. Note that this is not the configuration for these models when maintaining the stock fusebox orientation; for the original configuration use decal HCP13475.
$ 12.95



u7) Aftermarket fusebox BOTTOM GASKET for the above HCP378xx or HCP7153xx series 6-circuit fuseboxes. These fuseboxes have an "open" bottom, which would allow moisture and, eventually, corrosion to get into this otherwise sealed fuseblock. This die cut 1/16" thick rubber gasket has pre-punched mounting holes.

HCP382 Aftermarket 6-circuit fusebox BOTTOM GASKET:
$ 8.95



u71) Aftermarket fusebox WIRING EXTENSION KITS for the above HCP378xx or HCP7153xx series 6-circuit fuseboxes. Because the above replacement fuseboxes normally have to be slightly repositioned from the stock fusebox location (to insure adequate seat pan clearance), and due to the fact that the original lead wires coming off the main engine harness are crimped onto the original fusebox terminals (and will have to be cut a bit short during removal), these wiring harness extension kits are highly recommended to greatly simplify the installation of your new fusebox. The extra length of these wires gives you the option to locate your new fusebox in a variety of more suitable positions.

Each wiring kit comes complete with 12" lengths of the proper color-coded wire leads for each of the four original circuits with insulated female spade terminals (already attached to the fusebox end of each wire) and a full set of the proper size butt connectors for attaching the wire leads to the original main harness wires. The additional wire length allows you to place the fusebox virtually anywhere that you need (or want to), eliminating the frustrating task of cobbling together the additional extra wire leads to install the replacement fusebox.

HCP8553 Aftermarket WIRING EXTENSION KIT, contains all of the correct gauge and solid- and tracer-striped color wires to allow for the easy installation of any of our aftermarket 6-circuit enclosed fuseboxes in the following bikes: all XJ550, XJ650, XJ750 Maxim and Midnight Maxim, 1984 XJ750RL Seca, and XJ900RK, RL, N/FN, and F models.
$ 29.95

HCP8554 Aftermarket WIRING EXTENSION KIT, contains all of the correct gauge and solid- and tracer-striped color wires to allow for the easy installation of any of our aftermarket 6-circuit enclosed fuseboxes in the following bikes: all 1981-83 XJ750 Seca, all XJ750 Euro, and 1978-79 XS1100 models.
$ 29.95

HCP16766 Aftermarket WIRING EXTENSION KIT, contains all of the correct gauge and solid- and tracer-striped color wires to allow for the easy installation of any of our aftermarket 6-circuit enclosed fuseboxes in the following bikes: all XJ1100 and 1980-81 XS1100 models.
$ 29.95


HCP27207 Aftermarket fusebox wire OPTIONAL INSTALLATION HARDWARE KIT. This kit contains a full set of un-insulated butt connectors and heat-shrink tubing (as well as cable ties and harness clips) that is needed when hooking up the fusebox wires to the main harness wires. NOTE: all of our complete fusebox kits or fusebox wiring harness kits already contain a set of insulated wire connectors; this kit contains (basically) the same type of connectors, but they are the thinner, less-noticable un-insulated connectors, and appropriate lengths of heat-shrink tubing (to cover the un-insulated connectors after they are installed). Not an absolutely necessary kit to have ---- as noted, all of our complete fusebox kits and wiring harness kits already come with the bigger, bulkier insulated butt connectors --- but many people prefer these thinner, more streamlined connectors to create a more professional-looking and weatherproof method of attaching the fusebox wires to the main harness wires when using our aftermarket enclosed ATO fusebox kits. . Can be used with all of our aftermarket enclosed fusebox kits.
$ 9.95


HCP17820 Aftermarket fusebox POWER JUMPER WIRE, allows you to power up the two additional circuits in any of our enclosed 6-circuit fusebox kits. This jumper wire replaces the thick (14 gauge) tan wire in our HCP8553 or HCP8554 wire harness extension wire kits, and jumpers the power feed into the fusebox into the two additional "SPARE" circuit terminals. Plug-and-play operation, creates a neat, orderly, and safe power feed system for utilizing the two additional circuits. Includes a pair of 16-gauge female spade wire-end terminals for hooking up the accessory circuits to the outbound side of the fusebox (but no wire is included) NOTE: the wires used for the spare circuit power feeds in this power jumper wire are: HCP9547 (pink with black tracer stripe) for one circuit, and HCP9548 (purple with white tracer stripe) for the other circuit. Both are 16-gauge GXL wire, and can be used for circuits requiring up to 15 amps of current. Additional lengths of each of these wire can be ordered below, for the "outbound" side of your fusebox, so that you can color-code your accessory circuit wire runs with the same color wires.......a very professional touch.
$ 19.95



Accessory Color Wire:

Sometimes, you'll want to add electrical accessory circuits to you bike.....a cigarette lighter, heated grips, perhaps a power port for a GPS unit, etc......and in such situations, it's best to run a separate circuit, with its own unique color-coded wiring, in order to keep things neat and orderly, electrically-speaking. We offer the following unique colors (not used anywhere else on your bike) to help you safely and accurately identify any new circuits that you add.


HCP9547 Aftermarket GXL PINK with BLACK TRACER STRIPE WIRE, abbreviated P/B, 16-gauge. Sold per foot:
$ 2.95

HCP9547SET5 Aftermarket GXL PINK with BLACK TRACER STRIPE WIRE, abbreviated P/B, 16-gauge, 5-foot length:
$ 12.95

HCP9547SET10 Aftermarket GXL PINK with BLACK TRACER STRIPE WIRE, abbreviated P/B, 16-gauge, 10-foot length:
$ 19.95



HCP9548 Aftermarket GXL PURPLE with WHITE TRACER STRIPE WIRE, abbreviated Pu/W, 16-gauge. Sold per foot:
$ 2.95

HCP9548SET5 Aftermarket GXL PURPLE with WHITE TRACER STRIPE WIRE, abbreviated Pu/W, 16-gauge, 5-foot length:
$ 12.95

HCP9548SET10 Aftermarket GXL PURPLE with WHITE TRACER STRIPE WIRE, abbreviated Pu/W, 16-gauge, 10-foot length:
$ 19.95




Electrical System Chemicals and Supplies:

NOTE: it’s important to understand the difference between the two types of greases used with electrical connectors. Di-electric grease acts as an electrical insulator: it does not allow current to flow through it easily, and is basically used to “waterproof” a connector assembly. Although it is an insulator, the act of engaging two electrical connectors together (i.e. pushing a male connector into a female connector) will push away the grease on the metal-to-metal contact portion of the terminals, so those remain electrically conductive (good) while also insulating all the other surfaces against moisture and oxygen intrusion (very good). This insulating property of di-electric grease makes it great for use in connector shells, etc. as terminal corrosion is one of the greatest contributors to electrical system problems in vehicles (especially older ones)……this is why most modern vehicles use “sealed” connector shells (the most popular is the Delphi Automotive brand called “weather pack” or “weatherpak”) to keep oxygen and moisture away from the metal terminals. Although you can retrofit these style connectors to older harnesses, it takes a LOT of time, money, and effort to do so.

Now, contrast the insulating properties of di-electric grease to the electrically conductive properties of Conductive Grease, which, as its name implies, the grease itself (which contains many fine carbon particles) conducts electricity. Of course, being a “grease”, it too will also protect and insulate a terminal coated with it from moisture, corrosion, etc…..same as di-electric grease. But…it’s conductive, and if the terminal it coats is electrically “hot”, so is the grease (i.e. touching the grease alone will shock you!).

So a conductive grease is great when you need protection plus current flow……ideal for frame (or battery) grounds to the frame, etc. You could---if you are totally anally-retentive---coat (for instance) a battery post internally with conductive grease, and then cover all of that with di-electric grease.

So, think of these grease as two different electrical system “tools”, and use accordingly.


et2) Aftermarket electrical connector DI-ELECTRIC GREASE coats, insulates, and protects metal terminal connectors from exposure to air, thus preventing oxidation, the killer of electrical systems. Smear some of this goo on each and every one of your electrical connectors (after you've cleaned them with some sandpaper or terminal cleaner) and you'll be doing yourself a big favor!

HCP14059 Aftermarket packet of DI-ELECTRIC GREASE, single use 2-gram packet, enough to do a few light bulbs, terminals, etc.
$ 4.95

HCP7528 Aftermarket tube of DI-ELECTRIC GREASE, big 3-ounce squeeze tube.
$ 21.95

NOTE: the following 2 product(s) can only be shipped via ground transport (which thus eliminates the postal Priority Mail, postal Express Mail, or private carrier Expedited levels of service for this item) and cannot (and will not----don't even ask!) be shipped outside of the continental USA. Additionally, there may be a per-package weight or quantity restriction, and thus multiple-unit orders of this product may have to be shipped in separate packages and will incur additional shipping charges.

HCP20940 Aftermarket tube of DI-ELECTRIC GREASE, 3.3-ounce aerosol can of marine grade grease, with adjustable nozzle size to tailor the grease output bead size to minimize slop and waste and making application much easier. 1-2 cans will do all connectors on an entire bike harness.
$ 24.95



et14) Aftermarket electrical connector CONDUCTIVE GREASE coats and protects metal terminal connectors from exposure to air, thus preventing oxidation, the killer of electrical systems. Unlike the di-electric grease listed above, which is an insulator (non-conductive), this carbon-based grease is electrically conductive and has multiple applications (such as battery terminal posts (internally), frame grounds, etc.).

HCP27923 Aftermarket packet of CONDUCTIVE GREASE, single use 2-gram packet, enough to do a few light bulbs, terminals, etc. Even tiny amounts (that you can barely see) will create minimal electrical resistance, so be careful with this stuff around capacitors and such. It gets everywhere, will stain your hands and clothing and take three days to wash off, and smells like some of the worst goop you've ever smelled. Use a toothpick for application. Don't eat it. Wear gloves. 2-gram pouch goes a long way.
$ 6.95



cps2) Aftermarket high-quality CROCUS CLOTH. Unlike sandpaper or emery paper, crocus cloth is a super-fine, cloth-backed soft abrasive that doesn’t “shed” particles during use, and is just the thing for burnishing and polishing of copper electrical contact, like the alternator rotor and starter motor commutators. Sold in a 2” wide x 1-foot long strip, enough for polishing many a commutator or contact.

HCP21378 Aftermarket strip of CROCUS CLOTH, measures 12” x 2”. Each:
$ 4.95




NOTE: the following 3 product(s) can only be shipped via ground transport (which thus eliminates the postal Priority Mail, postal Express Mail, or private carrier Expedited levels of service for this item) and cannot (and will not----don't even ask!) be shipped outside of the continental USA. Additionally, there may be a per-package weight or quantity restriction, and thus multiple-unit orders of this product may have to be shipped in separate packages and will incur additional shipping charges.

HCP10493 Aftermarket battery post TERMINAL SEALER helps keep corrosion from forming on the battery terminals. Fast drying and leaves no residue. Comes in a 6-ounce aerosol can.
$ 12.95

HCP9762 Aftermarket miracle-goo black LIQUID ELECTRICAL TAPE is easier to use than traditional tape products, especially in close-in locations. Great for sealing crimped wire terminal ends to the wire and serves as a good alternative or supplement to shrink tubing. Just brush it on and let it dry! Comes in a 4-ounces brush-top can.
$12.95

HCP10508 Aftermarket electrical CONTACT CLEANER is a good general purpose cleaner and de-greaser. Will not harm plastic terminal connector blocks. Fast drying and leaves no residue. Comes in a 16-ounce aerosol can.
$ 14.95




HCP12923 Aftermarket harness bundle VINYL ELECTRICAL TAPE WRAP, black, 20-foot roll.
$ 8.95

HCP13134 Aftermarket harness bundle VINYL ELECTRICAL TAPE WRAP, black, 66-foot roll, almost enough to do one complete harness.
$ 16.95

Additionally, most harnesses had a few short turns of COLORED VINYL ELECTRICAL TAPE WRAP to provide visual identification of "what connector goes where?" during harness assembly and installation. Always located just by the connector shell, about 3-4 turns of this tape was used to both tape off any vinyl sleeve and to properly identify what the connector plugged into. Used primarily at the TCI connector (from the pick-up coils) and at the various small "cube" style relays (headlight relays, sidestand safety switch relays, etc.). Since all of these harness connector shells are the same style and type (4-position, horizontally oriented 2-over-2), this small tape wrap served as a way of indicating which of these many identical connectors went to which component.

HCP13130 Aftermarket harness bundle YELLOW VINYL ELECTRICAL TAPE WRAP, 20-foot roll. Used by the pick-up coil harness connector (at the TCI) on XJ700-X and XJ750-X models, and at the headlight relay connector on all XJ550 models, all XJ650 (except Turbo) models, and all XJ750 Seca models.
$ 7.95

HCP13131 Aftermarket harness bundle RED VINYL ELECTRICAL TAPE WRAP, 20-foot roll. Used by the pick-up coil harness connector (at the TCI) on 1982-83 XJ650 Maxim models, all '81-83 XJ750 models, and all XJ700 non-X models, and at the fuel pump relay connector on all XJ650 Turbo models.
$ 7.95

HCP13132 Aftermarket harness bundle BLUE VINYL ELECTRICAL TAPE WRAP, 20-foot roll. Used by the pick-up coil harness connector (at the TCI) on all XJ550 models, at the emergency stop switch relay connector on all XJ650 Turbo models, and for the sidestand safety switch relay connector on all XJ550 models, all '82-83 XJ650 models, all XJ750 models, XJ900RK and XJ1100 models.
$ 7.95

HCP13133 Aftermarket harness bundle GREEN VINYL ELECTRICAL TAPE WRAP, 20-foot roll. Used by the pick-up coil harness connector (at the TCI) on all XJ650RJ Seca and XJ1100 models.
$ 7.95




et26) Aftermarket electrical device SWITCH LUBRICANT is a specially formulated, electrically non-conductive penetrating lube that is recommended on control switch turn signal contacts and headlight switching contacts. 10-gram squeeze tube has applicator tip for precision use.

HCP14066 Aftermarket tube of electrical SWITCH LUBRICANT.
$ 16.95



et27) Aftermarket electrical INSTRUMENT OIL is a highly refined light oil for use on speedometer heads, tachometers, gauges, mechanical clocks, etc. Will not congeal even at 50-below-zero! Extra-slow rate of evaporation makes sure that it provides lubrication for a long, long time. 1-ounce pen has an applicator needle tip for precision use.

HCP20852 Aftermarket hi-performance INSTRUMENT OIL, comes in a handy applicator pen. Oil-based triple-processed lubricant eliminates contaminants that would cause gumming or corrosion product is what we use and recommend for freeing stuck fork tube cap bolts[/b][/color].
$ 37.95



HCP10540 Aftermarket acid-neutralizing BATTERY MAT, thin felt mat with pressure-treated with a battery-acid neutralizing chemical. Easily placed directly under the battery, it prevents any spills or discharge from the battery from doing damage to your paint, frame, etc. Trim to fit your battery box with a sharp knife or a pair of scissors. For all XJ550, XJ650, XJ700, XJ750, and XJ900RK models.
$ 9.95

HCP10541 Aftermarket acid-neutralizing BATTERY MAT, thin felt mat with pressure-treated with a battery-acid neutralizing chemical. Easily placed directly under the battery, it prevents any spills or discharge from the battery from doing damage to your paint, frame, etc. Trim to fit your battery tray with a sharp knife or a pair of scissors. For all XJ1100 models.
$ 13.95



HCP10580 Aftermarket acid-neutralizing BATTERY TERMINAL PROTECTORS, thin, round felt mat circles are pressure-treated with a battery-acid neutralizing chemical. Placed under the battery terminal posts, they help prevents any spills or discharge from the battery from creating terminal corrosion. Trim and size to fit your battery posts with a sharp knife or a pair of scissors. Order 1 per terminal, 2 per battery. Each:
$ 3.95




r) Replacement 8-CIRCUIT ENCLOSED FUSEBOX. This small, weatherproof ATC (mini push-in blade style fuse) fusebox is the most popular replacement for the stock glass-tube fusebox and is the type that many owners use. Same as the HCP378 fusebox above, but with two extra slots for a total of 8 circuits, in case you need to add even more circuits. Includes a total of eight ATC push-in style fuses, 2 x 20A and 6 x 10A.

Size: 4-1/2" long x 1-1/8" wide (not including the wire terminal spades) x 1-5/8" tall (including the clear cover). Note that this is a "bottom-terminal" design...the male spades point down towards the base of the fusebox, rather than out the sides. . THIS FEATURE CAN MAKE THE INSTALLATION OF THIS FUSEBOX TRICKY ON THESE BIKES, and the additional height of this box will cause interference problems between the fusebox cover and the bottom of the seat pan on stock bikes.

HCP379BC Aftermarket FUSEBOX, 8-circuit with a full set of standard style ATC push-in style fuses (6 x 10A, and 2 x 20A).
$ 16.95

HCP379LF Aftermarket FUSEBOX, 8-circuit with a full set of "glow-when-blown" indicator style ATC push-in style fuses (6 x 10A, and 2 x 20A).
$ 19.95



In-Line Fuseholders:

rf1) Aftermarket replacement individual INLINE FUSE HOLDER, heavy-duty waterproof style features a snap-close cap and accepts the standard or "glow-when-blown" type ATC/ATO push-in style fuses.

NOTE: on all XJ models except XJ700, 1982 XJ750 Maxim, XJ750 Seca, and XJ1100 models, the original fusebox uses a 20A fuse for the main circuit, and 10A fuses for the headlight, turn signals, and ignition circuits. Upgrading to a larger capacity fuse HOLDER poses no problems or issues, but [/b]NEVER[/b] use a larger fuse than the original rated capacity of a circuit (regardless of what "size" fuseholder you use on the circuit).

XJ700 models used a fuse panel (under the gauges) that already comes with ATC style fuses for the auxiliary circuits, and there is no need to upgrade that! However, the XJ700 models use a 30A main fuse in a separate in-line fuse holder that uses the old glass-style fuse, and that is certainly a candidate for updating with the 30A ATC style in-line fuse holder HCP6833 or HCP16777 listed below.

XJ1100 models used a standard style glass-fuses panel along with a 30A main fuse in a separate in-line fuse holder that uses the old glass-style fuse, and that is certainly a candidate for updating with the 30A ATC style in-line fuse holder HCP6833 or HCP16777 listed below.



HCP7122 Aftermarket standard IN-LINE FUSE HOLDER, solid colored thermoplastic housing, 6" long, 16-gauge wire leads, 10A capacity, each:
$ 3.95



HCP6833 Aftermarket standard IN-LINE FUSE HOLDER, solid colored thermoplastic housing, 6" long, 12-gauge wire leads, 30A capacity, each:
$ 4.95

HCP6833SET4 Aftermarket standard IN-LINE FUSE HOLDERS, solid colored thermoplastic housing, set of 4:
$ 17.95


HCP16777 Aftermarket MAIN FUSEHOLDER REPLACEMENT KIT, contains the weatherproof "blade" style HCP6833 main fuse holder with the white plastic connector shell that plugs into your main wiring harness (just like the original main fuseholder does).....no splicing, dicing, or harness chopping required! Includes 2 x 30A blade fuses (1 for use and 1 as a spare). Fits all XJ700, XJ750-X, XJ1100, and 1980-81 XS1100 models.
$ 16.95


HCP6834 Aftermarket see-through IN-LINE FUSE HOLDER, designed to be used with the "glow-when-blown" fuses, 4" long, 12-gauge wire leads, 20A capacity, each:
$ 7.95

HCP6834SET4 Aftermarket see-through IN-LINE FUSE HOLDERS, set of 4:
$ 29.95



Replacement Fuses:

rf2) Aftermarket replacement ATC/ATO FUSES, for use with the above 6- or 8-circuit replacement fuseboxes or the in-line fuseholders. Both the standard style and "Glow-When-Blown" fuses are high quality products that meet or exceed current vehicle manufacturer specifications.


HCP7149 Aftermarket standard type 5-AMP ATC/ATO FUSE, orange, push-in style, each:
$ 0.95

HCP7149SET5 Aftermarket standard type 5-AMP ATC/ATO FUSES, orange, push-in style, set of 5:
$ 3.95


HCP381 Aftermarket standard type 10-AMP ATC/ATO FUSE, red, push-in style, each:
$ 0.95

HCP381SET5 Aftermarket standard type 10-AMP ATC/ATO FUSES, red, push-in style, set of 5:
$ 3.95


HCP7150 Aftermarket standard type 15-AMP ATC/ATO FUSE, blue, push-in style, each:
$ 0.95

HCP7150SET5 Aftermarket standard type 15-AMP ATC/ATO FUSES, blue, push-in style, set of 5:
$ 3.95


HCP380 Aftermarket standard type 20-AMP ATC/ATO FUSE, yellow, push-in style, each:
$ 0.95

HCP380SET5 Aftermarket standard type 20-AMP ATC/ATO FUSES, yellow, push-in style, set of 5:
$ 3.95


HCP7151 Aftermarket standard type 30-AMP ATC/ATO FUSE, green, push-in style, each:
$ 0.95

HCP7151SET5 Aftermarket standard type 30-AMP ATC/ATO FUSES, green, set of 5:
$ 3.95


The following are innovative "Glow-When Blown" ATC/ATO mini-fuses that incorporate a small, bright indicator light that activates when the fuse blows, thus making the identification of a disrupted circuit easy to spot:


HCP7147 Aftermarket "GLOW-WHEN-BLOWN" 5-AMP ATC/ATO FUSE, tan, push-in style, each:
$ 2.95

HCP7147SET5 Aftermarket "GLOW-WHEN-BLOWN" 5-AMP ATC/ATO FUSES, tan, push-in style, set of 5:
$ 12.95


HCP6832 Aftermarket "GLOW-WHEN-BLOWN" 10-AMP ATC/ATO FUSE, red, push-in style, each:
$ 2.95

HCP6832SET5 Aftermarket "GLOW-WHEN-BLOWN" 10-AMP ATC/ATO FUSES, red, push-in style, set of 5:
$ 12.95


HCP7148 Aftermarket "GLOW-WHEN-BLOWN" 15-AMP ATC/ATO FUSE, blue, push-in style, each:
$ 2.95

HCP7148SET5 Aftermarket "GLOW-WHEN-BLOWN" 15-AMP ATC/ATO FUSES, blue, push-in style, set of 5:
$ 12.95


HCP6831 Aftermarket "GLOW-WHEN-BLOWN" 20-AMP ATC/ATO FUSE, yellow, push-in style, each:
$ 2.95

HCP6831SET5 Aftermarket "GLOW-WHEN-BLOWN" 20-AMP ATC/ATO FUSES, yellow, push-in style, set of 5:
$ 12.95


HCP7146 Aftermarket "GLOW-WHEN-BLOWN" 30-AMP ATC/ATO FUSE, green, push-in style, each:
$ 2.95

HCP7146SET5 Aftermarket "GLOW-WHEN-BLOWN" 30-AMP ATC/ATO FUSES, green, push-in style, set of 5:
$ 12.95[/i][/i]

 

SECTION D:

ELECTRICAL SYSTEM:

--Electrical System Wiring: Wiring harness components and related.



ELECTRICAL WIRE HARNESS PARTS: INTRODUCTION:

Wiring issues tend to cause quite a bit of confusion and distress to many people, for a variety of reasons, the foremost reason being that some electrical device isn't functioning properly, or at all! An that's when the intimidation starts to set in, staring at a maze of seemingly identical wires, connectors, terminals, etc............sometimes even hidden inside their protective sheathing.

We're here to help............with the physical aspects of your wiring system components, at least! Don't ask us about the electricity that flows inside those wires and terminals, though, it's a complete mystery to us, too..........

As a more familiar and easily understandable introduction to the entire wiring subject, let's take the case of a typical household situation: your toaster.


A toaster is what we will call a device. It is one of many types of devices that you can plug into the main electrical wiring harness that runs throughout your house (which starts at the fusebox or fuse panel located somewhere in your house). This main electrical wiring harness is normally hidden behind the sheetrock walls, and is normally only "visible" to you when an electrical outlet (or, a light switch, etc.) branches off of it and pokes thru the wall.

At that point, you see a wall outlet, the common three-place receptacle that you could plug your device (toaster, TV, computer, etc.) into. This wall "outlet" is actually composed of a few component pieces though:

- the wires that are part of that main wiring harness. In homes, which use AC current, you typically have 3 wires that go to each outlet: positive, negative, and a neutral. DC electrical systems, as used in most vehicles, typically only have a positive and a negative ("ground") wire as part of each circuit.

- each of those wires has, on each of its ends, a metal wire-end terminal that allows the physical interaction between two wires that are being hooked into one another to be secure.

- those three wires are all joined together, for organizational and safety purposes, into a plastic connector block or "shell". The wire, with their (typically, brass) metal end terminals, are placed within and permanently aligned and oriented in relation to one another within this connector block or shell.


Okay, so good so far........


But once you start thinking about it, that device that you want to power----the toaster, the TV, the whatever-----it also has a plastic connector block or shell on it, also. It's what we typically call a "plug", but once again, what we call a plug is really composed of the same three component parts: wires, a metal wire-end terminal which is attached to the end of each wire, and a plastic connector block or shell (called the "plug") that holds the wires and their end terminals in alignment.

And notice, that the device (the toaster) may have a long length of wire from it to its connector block or shell (called a "plug"). This long run of wire(s), with their attached end plug, is what we refer to as a "lead-in harness", since it "leads into" the device.


Now in order to get our Pop-tarts toasted, we must get power from the main wire harness to the toaster, and of course we do this by joining the connector block on the end of the toaster "lead-in" harness (the "plug") to the connector block on the end of the main house wire harness (the "outlet").

In other words, we "plug" (or "join") the connector block on the end of the "device" into the connector block from the main house harness (the "outlet").


Okay, I know the above explanation is kind of silly, but it's meant to help clarify what the descriptive terms are in a manner that is hopefully easy to understand. On your bike, there is a main wire harness, and this main harness has all types of branch circuits for each final-use device----such as your handlebar control switches, your headlight, each of your switches and relays, the regulator, each turn signal, the coils, etc.

Each branch circuit has the appropriate wires for the device it is being connected to, each device (well, most of them!) has its own lead-in harness, and at the point of connection there are wires, each with a metal wire-end terminal, and all housed together in a plastic connector block or shell. There is a connector block or shell on the device side of the connection, and a mating version of it on the main harness side of the connection.

Since the connector blocks are designed to "mate" together, there are both a "male" and "female" version of each style connector block that only mates into one of its own "kind" (unlike in your house, where most devices can plug into any main harness outlet). On your bike you want to plug in your coil connector only to its proper main harness circuit wiring, and thus different types (shapes, sizes, and colors) of connector blocks are used on each circuit. In this way, it insures that the handlebar switch (the device) can only be plugged into its proper main harness circuit mating connector shell that is on the main harness.


So when you read the description below, and it says that a particular connector shell is used on:

- Starter solenoid lead harness, on the main harness side of the connection: all XJ-series bikes (except all XJ700 and XJ750-X models).

now you will understand what that means-----that the particular connector shell being referenced is used on this particular "device" (in the above example, for the starter solenoid), and, it is used on the main harness "side" of the connection of this device to the main wiring harness. The "other side" of this joint would use the opposite mate of this same style connector block, and would be described as:

- Starter solenoid lead harness, on the solenoid lead-in harness side of the connection: all XJ-series bikes (except all XJ700 and XJ750-X models).

......and thus holds the wires and terminals that are on the short "lead-in" harness that actually goes into the starter solenoid (device) itself.


Also note that in some situation, the same style connectors can be used on different circuits, and for different devices, but are color-coded differently so as to distinguish one circuit from another.

Whew! Ain't electricity fun? If you get confused along the way, just holler, and we'll do our best to get you (and your harness) "connected" properly.




ELECTRICAL HARNESS WIRE:

But not just any kind of wire! We offer only the highest-quality GXL cross-linked PVC-coated wire in the correct gauge stranded copper core in both SOLID-COLOR and TRACER-STRIPE WIRE. This wire is far superior to common chain-store wire and is available in most of the original tracer-stripe color coding scheme so you can keep your harness original or build a new harness and still trace your circuits properly.

A brief comparison illustrates the superiority of GXL wire versus standard wire: most "regular" automotive-grade wire is designated as a "GPT" grade of extruded PVC wire, and it is rated for -40 to +80-C temperatures. This type wire, if it gets hot enough, will not only melt, but it will also catch on fire.....a great way to ruin your day, your wire harness, your bike, etc. GPT grade wire is basically what was used originally by Yamaha in your harness, and is normally what you can buy in retail home-improvement and hardware stores. It is created by heating PVC and then quickly extruding it through a die over a particular size of stranded (or solid) wire core.

GXL grade wire, although still a PVC-based product, is formed by extruding PVC through a tube, under intense heat and pressure, in order to 'cross-link' and change the molecular properties of the insulation to a much more durable state. This is why GXL wire is rated for use from -51 to +125-C (225-F) temperatures. Additionally, although GXL wire will still melt when its heat rating is exceeded, it is not flammable, and that may be a very important consideration for you should a short ever develop within your electrical system someday..........


What size is my wire?:

Unfortunately, factory wiring diagrams indicate almost every other parameter about your wiring harness----wire color, wire connector type, where it goes to and where it comes from and where it's spliced together, etc.-----but does not specify the wire gauge (or size) of the wires used.

A little bit on wire "gauge" sizes. The gauge of a wire is basically what size the inner wire core is, and that size determines the wire current-carrying capacity. The lower the gauge number, the larger the wire size and thus current-handling capacity. Thus a 14-gauge wire is larger (physically and in current carrying capacity) than a 16-gauge, or an 18-gauge, or a 20-gauge, etc. size wire.


Yes, we know that's "backwards", but that's the way it is. In fact, wire gauges (often noted as "AWG", which stands for American Wire Gauge Standard----and yes, there is also a metric wire sizing "standards", too!) are really a medieval sort of thing.....for example, you are holding a piece of wire in your hand----perhaps the solid white wire that goes to your alternator stator----and you're wondering "what gauge wire is this?" I mean, you really do want to know that information, since you want to replace it with that gauge wire or larger (meaning a "lower" number wire gauge size), but never a smaller (= a higher wire gauge size) wire, as the original wire is designed to carry a certain amount of electrical energy, and substituting a smaller wire size could cause voltage loss (think: dim headlights, overcharged batteries, overheated wires, melted connectors, a small fire starting somewhere near your gas tank, etc.-------all sorts of devastation, electrically-speaking).


So how to you determine what size wire is in your hand? Well, this is kind of confusing, but here goes:

- for stranded-core wire (which is what is used on most vehicular applications, including these bikes), you should do the following:

* Make a small cut about 1/2" long and remove the insulation from the wire.
* Then you will need to count the individual strands of copper....how many individual strands are there?
* Next, use a micrometer and measure the thickness of any one single strand.
* Then, look at the following information to determine the gauge of your automotive wire:

# of strands / diameter of each wire strand

7 x .028" = 20-gauge wire
(this example means that a 20-gauge wire has 7 individual wire strands, each strand measuring .028" in diameter)

16 x .030" =18-gauge wire
19 x .029" =16-gauge wire
19 x .027" =14-gauge wire
19 x .025" =12-gauge wire
19 x .023" =10-gauge wire
19 x .021" = 08-gauge wire
37 x .021" = 06-gauge wire


Wow, that's a lot of work, isn't it?

Here's the shortcut method that applies to your harness wires.........you measure the outside diameter of the wire in your hand (meaning, the O.D. of the insulation) and that measurement tells you what the AWG of the wire core is. NOTE: make sure that you measure the wire on a straight portion of the wire, and it's useful to take 2 or 3 different measurements to make sure you are not measuring a distorted, "egg-shaped" area of the insulation:

If the wire OD is 2.03mm - 2.19mm (.0799 to .0862"), then it's 20-gauge (20g) AWG or 0.40mm squared (metric size).
NOTE: 20g wire is rated for a maximum load of 11 amps of current at 12VDC.

If the wire OD is 2.26mm - 2.42mm (.0890 to .0953"), then it's 18-gauge (18g) AWG or 0.75mm squared (metric size).
NOTE: 18g wire is rated for a maximum load of 16 amps of current at 12VDC.

If the wire OD is 2.48mm - 2.64mm (.0976 to .1039"), then it's 16-gauge (16g) AWG or 1.25mm squared (metric size).
NOTE: 16g wire is rated for a maximum load of 22 amps of current at 12VDC.

If the wire OD is 2.89mm - 3.05mm (.1138 to .1201"), then it's 14-gauge (14g) AWG or 2.00mm squared (metric size).
NOTE: 14g wire is rated for a maximum load of 32 amps of current at 12VDC.
NOTE: 14g wire is the largest size wire normally found in the wiring harnesses on these bikes. Battery cables and the solenoid-to-starter motor cable are larger, of course, but of all the main harness and accessory wiring, 14-gauge is the largest that you'll find.

If the wire OD is 3.49mm - 3.65mm (.1374 to .1437"), then it's 12-gauge (12g) AWG or 3.00mm squared (metric size).
NOTE: 12g wire is rated for a maximum load of 41 amps of current at 12VDC.

If the wire OD is 4.32mm - 4.48mm (.1701 to .1764"), then it's 10-gauge (10g) AWG or 5.00mm squared (metric size).
NOTE: 10g wire is rated for a maximum load of 55 amps of current at 12VDC.


So, for example, if you measure your white alternator stator lead wires, you'll find them to be about .1015" in outer diameter, and referring to the chart above, you determine that they are thus 16-gauge wire. And therefore you should always replace them, if needed, with 16-gauge or larger wire (meaning 16-gauge, 14-gauge, 12-gauge, etc.).

If you measure your solid red harness lead wire that comes off your solenoid or regulator unit----which is the main power supply for your harness-----you might find it measures about .1185" in diameter. Again referring to the chart above, it is therefore a 14-gauge wire.


REMEMBER: always use the same-size (gauge) wire as original or a larger size (a numerically smaller gauge size) or otherwise you are setting yourself up for major problems and the risk of fire!



What color is my wire?:

There are two different formats of wire insulation colors in your harness:

* solid colored wire, which is pretty self-explanatory, and.....
* tracer wire, which is a solid color wire imprinted with a permanent, straight, contrasting-color stripe along its entire length. This "tracer stripe" makes it easy to identify any particular wire and what circuit it belongs to.

For the sake of both clarity, future troubleshooting, and safety, we always strongly urge people to replace wires with the same color and format (solid color vs. tracer-stripe) wire as was originally used, or, if you're building your own custom harness, to follow the same color-coding standards as what was originally used by Yamaha (for example: the main power feed wire for the harness is a solid red wire; solid black wires are ground circuit wires; a solid yellow wire is the rear brake light wire; a horn wire is a solid pink wire; the coils are fed by a solid orange wire, a solid grey wire, and a red wire with a white tracer stripe, etc.).

This attention to detail make for a professional harness build or repair, and greatly simplifies your life in the future!


In your factory wire diagram, solid color wires are identified by their solid color abbreviation, which are:

B = Black
Br = Light Brown
Ch = Chocolate Brown, which is a very dark brown, almost black.
Dg = Dark green, which is a very dark green, almost black.
Gr = Green, which could be a light or medium green color.
Gy = Grey, which is a light grey color
L = Blue, which could be a medium or a navy blue or even a very dark blue, almost black.
P = Pink
O = Orange, which is a bright orange
R = Red
Sb = Light Blue or "Sky" Blue, a very light, baby-blue color.
W = White
Y = Yellow, which is a bright yellow

So a solid Black wire would be coded as "B", while a solid Light Brown wire appears as "Br", while a Dark "Chocolate" Brown wire is abbreviated as "Ch".


Tracer wires are identified first by their primary wire color abbreviation (from the chart above), and then a slash mark (/), followed by the tracer stripe color abbreviation.

So for instance, a Black (B) wire that has a thin Yellow (Y) tracer stripe will appear on the diagrams as B/Y or
B/y (the lower case letter makes the identify of the "tracer" color more obvious).

A Red (R) wire with a white tracer stripe would be labeled as R/W (or R/w), while a Red wire with a black tracer stripe would be R/B (or R/b).

Be aware that some tracer stripe colors are very difficult to tell apart from each other (particularly white vs. yellow tracer stripes), while other tracer stripe colors are just hard to see because of the lack of color contrast (for instance, a dark blue wire with a black tracer stripe).



Solid Black (B) Wire:

Used for various harness ground wires, this wire can vary in size from 20-gauge (which is not available, use the next larger size 18-gauge instead) all the way down to 12-gauge, so make sure you measure the wire size you need and order the correct size. If in doubt, use the largest size possible!


HCP1323 Aftermarket GXL SOLID BLACK WIRE, abbreviated as "B" in factory wiring diagrams, 18-gauge. Sold per foot:
$ 1.95

HCP1323SET5 Aftermarket GXL SOLID BLACK WIRE, abbreviated as "B" in factory wiring diagrams, 18-gauge, 5-foot length:
$ 8.95

HCP1323SET10 Aftermarket GXL SOLID BLACK WIRE, abbreviated as "B" in factory wiring diagrams, 18-gauge, 10-foot length:
$ 16.95

HCP1323SET25 Aftermarket GXL SOLID BLACK WIRE, abbreviated as "B" in factory wiring diagrams, 18-gauge, 25-foot length:
$ 29.95



HCP12944 Aftermarket GPT SOLID BLACK CLOTH-COVERED WIRE, abbreviated as "B" in factory wiring diagrams, 18-gauge cloth-covered. This wire is used on the alternator rotor brushes lead harness on XJ1100 models only. Sold per foot:
$ 2.95

HCP12944SET5 Aftermarket GPT SOLID BLACK CLOTH-COVERED WIRE, abbreviated as "B" in factory wiring diagrams, 18-gauge, cloth-covered, 5-foot length:
$ 12.95



HCP9515 Aftermarket GXL SOLID BLACK WIRE, abbreviated as "B" in factory wiring diagrams, 16-gauge. Sold per foot:
$ 2.95

HCP9515SET5 Aftermarket GXL SOLID BLACK WIRE, abbreviated as "B" in factory wiring diagrams, 16-gauge, 5-foot length:
$ 12.95

HCP9515SET10 Aftermarket GXL SOLID BLACK WIRE, abbreviated as "B" in factory wiring diagrams, 16-gauge, 10-foot length:
$ 19.95

HCP9515SET25 Aftermarket GXL SOLID BLACK WIRE, abbreviated as "B" in factory wiring diagrams, 16-gauge, 25-foot length:
$ 39.95



HCP9517 Aftermarket GXL SOLID BLACK WIRE, abbreviated as "B" in factory wiring diagrams, 14-gauge. Sold per foot:
$ 2.95

HCP9517SET5 Aftermarket GXL SOLID BLACK WIRE, abbreviated as "B" in factory wiring diagrams, 14-gauge, 5-foot length:
$ 12.95

HCP9517SET10 Aftermarket GXL SOLID BLACK WIRE, abbreviated as "B" in factory wiring diagrams, 14-gauge, 10-foot length:
$ 19.95

HCP9517SET25 Aftermarket GXL SOLID BLACK WIRE, abbreviated as "B" in factory wiring diagrams, 14-gauge, 25-foot length:
$ 39.95



HCP1324 Aftermarket GXL SOLID BLACK WIRE, abbreviated as "B" in factory wiring diagrams, 12-gauge. Sold per foot:
$ 2.95

HCP1324SET5 Aftermarket GXL SOLID BLACK WIRE, abbreviated as "B" in factory wiring diagrams, 12-gauge, 5-foot length:
$ 12.95

HCP1324SET10 Aftermarket GXL SOLID BLACK WIRE, abbreviated as "B" in factory wiring diagrams, 12-gauge, 10-foot length:
$ 19.95

HCP1324SET25 Aftermarket GXL SOLID BLACK WIRE, abbreviated as "B" in factory wiring diagrams, 12-gauge, 25-foot length:
$ 39.95



Black Tracer Wire:

Used in a variety of places---mostly for sensors and safety relays---are used throughout many harnesses. Please note that it is sometimes very difficult on original harnesses to visually tell the difference between a white and a yellow tracer stripe, so make sure you view it under s good light or consult a factory wiring diagram to be sure!

NOTE: many of the original wires on your harness will be 20-gauge. We do not offer 20-gauge wire and recommend that you substitute the slightly larger 18-gauge wire in place of it.


HCP1335 Aftermarket GXL BLACK with RED TRACER STRIPE WIRE, abbreviated as "B/R" in factory wiring diagrams, 18-gauge. Sold per foot:
$ 1.95

HCP1335SET5 Aftermarket GXL BLACK with RED TRACER STRIPE WIRE, abbreviated as "B/R" in factory wiring diagrams, 18-gauge, 5-foot length:
$ 8.95

HCP1335SET10 Aftermarket GXL BLACK with RED TRACER STRIPE WIRE, abbreviated as "B/R" in factory wiring diagrams, 18-gauge, 10-foot length:
$ 16.95

HCP1335SET25 Aftermarket GXL BLACK with RED TRACER STRIPE WIRE, abbreviated as "B/R" in factory wiring diagrams, 18-gauge, 25-foot length:
$ 29.95



HCP9519 Aftermarket GXL BLACK with WHITE TRACER STRIPE WIRE, abbreviated as "B/W" in factory wiring diagrams, 18-gauge. Sold per foot:
$ 1.95

HCP9519SET5 Aftermarket GXL BLACK with WHITE TRACER STRIPE WIRE, abbreviated as "B/W" in factory wiring diagrams, 18-gauge, 5-foot length:
$ 8.95

HCP9519SET10 Aftermarket GXL BLACK with WHITE TRACER STRIPE WIRE, abbreviated as "B/W" in factory wiring diagrams, 18-gauge, 10-foot length:
$ 16.95

HCP9519SET25 Aftermarket GXL BLACK with WHITE TRACER STRIPE WIRE, abbreviated as "B/W" in factory wiring diagrams, 18-gauge, 25-foot length:
$ 29.95



HCP1336 Aftermarket GXL BLACK with YELLOW TRACER STRIPE WIRE, abbreviated as "B/Y" in factory wiring diagrams, 18-gauge. Sold per foot:
$ 1.95

HCP1336SET5 Aftermarket GXL BLACK with YELLOW TRACER STRIPE WIRE, abbreviated as "B/Y" in factory wiring diagrams, 18-gauge, 5-foot length:
$ 8.95

HCP1336SET10 Aftermarket GXL BLACK with YELLOW TRACER STRIPE WIRE, abbreviated as "B/Y" in factory wiring diagrams, 18-gauge, 10-foot length:
$ 16.95

HCP1336SET25 Aftermarket GXL BLACK with YELLOW TRACER STRIPE WIRE, abbreviated as "B/Y" in factory wiring diagrams, 18-gauge, 25-foot length:
$ 29.95



Solid Blue Wire:

Although the factory wiring diagrams only specified the difference between the Sky Blue ("Sb") color and a generic Blue ("L") color in their wiring diagrams, there were in fact a number of different shades of "blue", with only the Sky Blue color being somewhat consistent.

- Sky Blue (abbreviated as "Sb" in factory wire diagrams), which is a very pale baby blue color. Your neutral switch and starting circuit cut-off relay use this color wire.
- Blue (abbreviated as "L" in factory wire diagrams), which may be either a:
- Light Blue.
- Medium Blue.
- Dark Blue-------which is a very, very dark (almost black) shade of blue.

We offer a "Light Blue" color which is slightly darker than the Sky Blue color, and a Dark Blue, which a very dark blue color.

The solid blue wires (besides the Sky Blue) are normally used for the rear tail light circuit and some of the dash lighting circuits.

NOTE: many of the original wires on your harness will be 20-gauge. We do not offer 20-gauge wire and recommend that you substitute the slightly larger 18-gauge wire in place of it.


HCP1332 Aftermarket GXL SOLID SKY BLUE WIRE, abbreviated as "Sb" in factory wiring diagrams, 18-gauge. Sold per foot:
$ 1.95

HCP1332SET5 Aftermarket GXL SOLID SKY BLUE WIRE, abbreviated as "Sb" in factory wiring diagrams, 18-gauge, 5-foot length:
$ 8.95

HCP1332SET10 Aftermarket GXL SOLID SKY BLUE WIRE, abbreviated as "Sb" in factory wiring diagrams, 18-gauge, 10-foot length:
$ 16.95

HCP1332SET25 Aftermarket GXL SOLID SKY BLUE WIRE, abbreviated as "Sb" in factory wiring diagrams, 18-gauge, 25-foot length:
$ 29.95



HCP1329 Aftermarket GXL SOLID DARK BLUE WIRE, abbreviated as "L" in factory wiring diagrams, 18-gauge. Sold per foot:
$ 1.95

HCP1329SET5 Aftermarket GXL SOLID DARK BLUE WIRE, abbreviated as "L" in factory wiring diagrams, 18-gauge, 5-foot length:
$ 8.95

HCP1329SET10 Aftermarket GXL SOLID DARK BLUE WIRE, abbreviated as "L" in factory wiring diagrams, 18-gauge, 10-foot length:
$ 16.95

HCP1329SET25 Aftermarket GXL SOLID DARK BLUE WIRE, abbreviated as "L" in factory wiring diagrams, 18-gauge, 25-foot length:
$ 29.95



Blue Tracer Wire:

Primarily found in switch or relay wiring circuits, most of these wires were originally 20-gauge. Since we do not offer 20-gauge wire, we recommend that you substitute the slightly larger 18-gauge wire in place of it.


HCP9525 Aftermarket GXL LIGHT BLUE with BLACK TRACER STRIPE WIRE, abbreviated as "L/B" in factory wiring diagrams, 18-gauge. Sold per foot:
$ 1.95

HCP9525SET5 Aftermarket GXL LIGHT BLUE with BLACK TRACER STRIPE WIRE, abbreviated as "L/B" in factory wiring diagrams, 18-gauge, 5-foot length:
$ 8.95

HCP9525SET10 Aftermarket GXL LIGHT BLUE with BLACK TRACER STRIPE WIRE, abbreviated as "L/B" in factory wiring diagrams, 18-gauge, 10-foot length:
$ 16.95

HCP9525SET25 Aftermarket GXL LIGHT BLUE with BLACK TRACER STRIPE WIRE, abbreviated as "L/B" in factory wiring diagrams, 18-gauge, 25-foot length:
$ 29.95



HCP1339 Aftermarket GXL DARK BLUE with BLACK TRACER STRIPE WIRE, abbreviated as "L/B" in factory wiring diagrams, 18-gauge. Sold per foot:
$ 1.95

HCP1339SET5 Aftermarket GXL DARK BLUE with BLACK TRACER STRIPE WIRE, abbreviated as "L/B" in factory wiring diagrams, 18-gauge, 5-foot length:
$ 8.95

HCP1339SET10 Aftermarket GXL DARK BLUE with BLACK TRACER STRIPE WIRE, abbreviated as "L/B" in factory wiring diagrams, 18-gauge, 10-foot length:
$ 16.95

HCP1339SET25 Aftermarket GXL DARK BLUE with BLACK TRACER STRIPE WIRE, abbreviated as "L/B" in factory wiring diagrams, 18-gauge, 25-foot length:
$ 29.95



HCP9520 Aftermarket GXL LIGHT BLUE with BLACK TRACER STRIPE WIRE, abbreviated as "L/B" in factory wiring diagrams, 16-gauge. Sold per foot:
$ 2.95

HCP9520SET5 Aftermarket GXL LIGHT BLUE with BLACK TRACER STRIPE WIRE, abbreviated as "L/B" in factory wiring diagrams, 16-gauge, 5-foot length:
$ 12.95

HCP9520SET10 Aftermarket GXL LIGHT BLUE with BLACK TRACER STRIPE WIRE, abbreviated as "L/B" in factory wiring diagrams, 16-gauge, 10-foot length:
$ 19.95

HCP9520SET25 Aftermarket GXL LIGHT BLUE with BLACK TRACER STRIPE WIRE, abbreviated as "L/B" in factory wiring diagrams, 16-gauge, 25-foot length:
$ 39.95



HCP1340 Aftermarket GXL DARK BLUE with WHITE TRACER STRIPE WIRE, abbreviated as "L/W" in factory wiring diagrams, 18-gauge. Sold per foot:
$ 1.975

HCP1340SET5 Aftermarket GXL DARK BLUE with WHITE TRACER STRIPE WIRE, abbreviated as "L/W" in factory wiring diagrams, 18-gauge, 5-foot length:
$ 8.95

HCP1340SET10 Aftermarket GXL DARK BLUE with WHITE TRACER STRIPE WIRE, abbreviated as "L/W" in factory wiring diagrams, 18-gauge, 10-foot length:
$ 16.95

HCP1340SET25 Aftermarket GXL DARK BLUE with WHITE TRACER STRIPE WIRE, abbreviated as "L/W" in factory wiring diagrams, 18-gauge, 25-foot length:
$ 29.95



HCP1341 Aftermarket GXL LIGHT BLUE with YELLOW TRACER STRIPE WIRE, abbreviated as "L/Y" in factory wiring diagrams, 18-gauge. NOTE: original harness wire color was always a dark blue, not this light blue color, when used with a yellow tracer stripe. Sold per foot:
$ 1.95

HCP1341SET5 Aftermarket GXL LIGHT BLUE with YELLOW TRACER STRIPE WIRE, abbreviated as "L/Y" in factory wiring diagrams, 18-gauge, 5-foot length:
$ 8.95

HCP1341SET10 Aftermarket GXL LIGHT BLUE with YELLOW TRACER STRIPE WIRE, abbreviated as "L/Y" in factory wiring diagrams, 18-gauge, 10-foot length:
$ 16.95

HCP1341SET25 Aftermarket GXL LIGHT BLUE with YELLOW TRACER STRIPE WIRE, abbreviated as "L/Y" in factory wiring diagrams, 18-gauge, 25-foot length:
$ 29.95



HCP9524 Aftermarket GPT DARK BLUE with YELLOW TRACER STRIPE WIRE, abbreviated as "L/Y" in factory wiring diagrams, 18-gauge. NOTE: original harness wire color was always a dark blue color when used with a yellow tracer stripe. This wire is the correct shade of blue, but it is formed using a lower grade of vinyl insulation (GPT) rather than the GXL wire used in most of the other wiring that we offer. Sold per foot:
$ 1.95

HCP9524SET5 Aftermarket GPT DARK BLUE with YELLOW TRACER STRIPE WIRE, abbreviated as "L/Y" in factory wiring diagrams, 18-gauge, 5-foot length:
$ 8.95

HCP9524SET10 Aftermarket GPT DARK BLUE with YELLOW TRACER STRIPE WIRE, abbreviated as "L/Y" in factory wiring diagrams, 18-gauge, 25-foot length:
$ 16.95

HCP9524SET10 Aftermarket GPT DARK BLUE with YELLOW TRACER STRIPE WIRE, abbreviated as "L/Y" in factory wiring diagrams, 18-gauge, 25-foot length:
$ 29.95



Solid Brown Wire:

Originally, there were 2 shades of brown wire used on original harnesses:

- Light Brown (abbreviated as "Br" in factory wire diagrams), which is a light or medium shade of brown. This wire is used in a variety of places within the harness; it is one of the most commonly used wire colors. Note that the main power feed from the ignition switch to the fusebox is brown, and it is a 14-gauge wire.

- Dark Brown (abbreviated as "Ch" in factory wire diagrams, for "Chocolate") and is a very, very dark----almost black----shade of brown). Your turn signal circuit uses this shade of brown wire.

We offer a Light Tan colored GXL wire which can be substituted for the Light Brown (Br) wire, as well as an actual Light Brown (Br) colored GPT grade wire. The GPT grade wire is not as durable as the GXL wire, but it is a much closer match to the original in color.

The Dark Brown colored wire is a very close to the original Dark "Chocolate" Brown (Ch) shade of brown.

NOTE: many of the original wires on your harness will be 20-gauge. We do not offer 20-gauge wire and recommend that you substitute the slightly larger 18-gauge wire in place of it.


HCP12843 Aftermarket GXL SOLID TAN WIRE, abbreviated as "Br" in factory wiring diagrams, 14-gauge. Sold per foot:
$ 2.95

HCP12843SET5 Aftermarket GXL SOLID TAN WIRE, abbreviated as "Br" in factory wiring diagrams, 14-gauge, 5-foot length:
$ 12.95

HCP12843SET10 Aftermarket GXL SOLID TAN WIRE, abbreviated as "Br" in factory wiring diagrams, 14-gauge, 10-foot length:
$ 19.95

HCP12843SET25 Aftermarket GXL SOLID TAN WIRE, abbreviated as "Br" in factory wiring diagrams, 14-gauge, 25-foot length:
$ 39.95



HCP27174 Aftermarket GXL SOLID TAN WIRE, slightly lighter in color as the wire that is abbreviated as "Br" (light brown) in factory wiring diagrams, 16-gauge. Sold per foot:
$ 1.95

HCP27174SET5 Aftermarket GXL SOLID TAN WIRE, slightly lighter in color as the wire that is abbreviated as "Br" (light brown) in factory wiring diagrams, 16-gauge, 5-foot length:
$ 8.95

HCP27174SET10 Aftermarket GXL SOLID TAN WIRE, slightly lighter in color as the wire that is abbreviated as "Br" (light brown) in factory wiring diagrams, 16-gauge, 10-foot length:
$ 16.95

HCP27174SET25 Aftermarket GXL SOLID TAN WIRE, slightly lighter in color as the wire that is abbreviated as "Br" (light brown) in factory wiring diagrams, 16-gauge, 25-foot length:
$ 29.95



HCP392 Aftermarket GXL SOLID TAN WIRE, slightly lighter in color as the wire that is abbreviated as "Br" (light brown) in factory wiring diagrams, 18-gauge. Sold per foot:
$ 1.95

HCP392SET5 Aftermarket GXL SOLID TAN WIRE, slightly lighter in color as the wire that is abbreviated as "Br" (light brown) in factory wiring diagrams, 18-gauge, 5-foot length:
$ 8.95

HCP392SET10 Aftermarket GXL SOLID TAN WIRE, slightly lighter in color as the wire that is abbreviated as "Br" (light brown) in factory wiring diagrams, 18-gauge, 10-foot length:
$ 16.95

HCP392SET25 Aftermarket GXL SOLID TAN WIRE, slightly lighter in color as the wire that is abbreviated as "Br" (light brown) in factory wiring diagrams, 18-gauge, 25-foot length:
$ 29.95



HCP15355 Aftermarket GPT LIGHT BROWN WIRE, abbreviated as "Br" in factory wiring diagrams, 14-gauge. Sold per foot:
$ 2.95

HCP15355SET5 Aftermarket GPT LIGHT BROWN WIRE, abbreviated as "Br" in factory wiring diagrams, 14-gauge, 5-foot length:
$ 12.95

HCP15355SET10 Aftermarket GPT LIGHT BROWN WIRE, abbreviated as "Br" in factory wiring diagrams, 14-gauge, 10-foot length:
$ 19.95

HCP15355SET25 Aftermarket GPT LIGHT BROWN WIRE, abbreviated as "Br" in factory wiring diagrams, 14-gauge, 25-foot length:
$ 39.95



HCP15354 Aftermarket GPT LIGHT BROWN WIRE, abbreviated as "Br" in factory wiring diagrams, 18-gauge. Sold per foot:
$ 1.95

HCP15354SET5 Aftermarket GPT LIGHT BROWN WIRE, abbreviated as "Br" in factory wiring diagrams, 18-gauge, 5-foot length:
$ 8.95

HCP15354SET10 Aftermarket GPT LIGHT BROWN WIRE, abbreviated as "Br" in factory wiring diagrams, 18-gauge, 10-foot length:
$ 16.95

HCP15354SET25 Aftermarket GPT LIGHT BROWN WIRE, abbreviated as "Br" in factory wiring diagrams, 18-gauge, 25-foot length:
$ 29.95



HCP27173 Aftermarket GXL SOLID DARK "CHOCOLATE" BROWN WIRE, abbreviated as "Ch" in factory wiring diagrams, 16-gauge. Sold per foot:
$ 1.95

HCP27173SET5 Aftermarket GXL SOLID DARK "CHOCOLATE" BROWN WIRE, abbreviated as "Ch" in factory wiring diagrams, 16-gauge, 5-foot length:
$ 8.95

HCP27173SET10 Aftermarket GXL SOLID DARK "CHOCOLATE" BROWN WIRE, abbreviated as "Ch" in factory wiring diagrams, 16-gauge, 10-foot length:
$ 16.95

HCP27173SET25 Aftermarket GXL SOLID DARK "CHOCOLATE" BROWN WIRE, abbreviated as "Ch" in factory wiring diagrams, 16-gauge, 25-foot length:
$ 29.95



HCP1325 Aftermarket GXL SOLID DARK "CHOCOLATE" BROWN WIRE, abbreviated as "Ch" in factory wiring diagrams, 18-gauge. Sold per foot:
$ 1.95

HCP1325SET5 Aftermarket GXL SOLID DARK "CHOCOLATE" BROWN WIRE, abbreviated as "Ch" in factory wiring diagrams, 18-gauge, 5-foot length:
$ 8.95

HCP1325SET10 Aftermarket GXL SOLID DARK "CHOCOLATE" BROWN WIRE, abbreviated as "Ch" in factory wiring diagrams, 18-gauge, 10-foot length:
$ 16.95

HCP1325SET25 Aftermarket GXL SOLID DARK "CHOCOLATE" BROWN WIRE, abbreviated as "Ch" in factory wiring diagrams, 18-gauge, 25-foot length:
$ 29.95



HCP12943 Aftermarket GPT SOLID BROWN CLOTH-COVERED WIRE, abbreviated as "B" in factory wiring diagrams, 18-gauge cloth-covered. This wire is used only on the alternator rotor brushes lead harness on all bikes except XJ1100 models. Use with the HCP14154 harness sheathing. Sold per foot:
$ 2.95

HCP12943SET5 Aftermarket GPT SOLID BROWN CLOTH-COVERED WIRE, abbreviated as "B" in factory wiring diagrams, 18-gauge cloth-covered, 5-foot length:
$ 12.95

HCP12943SET10 Aftermarket GPT SOLID BROWN CLOTH-COVERED WIRE, abbreviated as "B" in factory wiring diagrams, 18-gauge cloth-covered, 10-foot length:
$ 19.95




Brown Tracer Wire:

Used for the turn signal flasher circuit only, this light brown wire with a white tracer stripe was originally 20-gauge wire, and is only offered as an 18-gauge replacement wire.

As noted above, we do not have the correct shade of the original Light Brown (Br) wire available, but offer this "Light Tan" wire color as a good substitute.


HCP13007 Aftermarket GXL TAN with WHITE TRACER STRIPE WIRE, abbreviated as "Br/W" in factory wiring diagrams, 18-gauge. Sold per foot:
$ 1.95

HCP13007SET5 Aftermarket GXL TAN with WHITE TRACER STRIPE WIRE, abbreviated as "Br/W" in factory wiring diagrams, 18-gauge, 5-foot length:
$ 8.95

HCP13007SET10 Aftermarket GXL TAN with WHITE TRACER STRIPE WIRE, abbreviated as "Br/W" in factory wiring diagrams, 18-gauge, 10-foot length:
$ 16.95

HCP13007SET25 Aftermarket GXL TAN with WHITE TRACER STRIPE WIRE, abbreviated as "Br/W" in factory wiring diagrams, 18-gauge, 25-foot length:
$ 29.95



Solid Green Wire:

Originally, there were 2 shades of green wire used on original harnesses:

- Green (abbreviated as "Gr" in factory wire diagrams), which may be either a:
- Light Green wire.
- Medium Green wire.

The above colors are used for the headlight circuit and for the alternator rotor. Note that the solid green wires coming from the alternator rotor brush plate itself is a braided-cloth covered wire, and the standard plastic insulated wire that we offer should not be substituted for the cloth-covered wire.

- Dark Green (abbreviated as "Dg" in factory wire diagrams) and is a very, very dark----almost black----shade of green). Your turn signal circuit uses this shade of green wire.

The "Green" (G) wire could be either the Light or the Medium Green color. It is not unusual for an original harness to have multiple color variations of "Green" wire.


HCP1327 Aftermarket GXL SOLID LIGHT GREEN WIRE, abbreviated as "G" in factory wiring diagrams, 18-gauge. Sold per foot:
$ 1.95

HCP1327SET5 Aftermarket GXL SOLID LIGHT GREEN WIRE, abbreviated as "G" in factory wiring diagrams, 18-gauge, 5-foot length:
$ 8.95

HCP1327SET10 Aftermarket GXL SOLID LIGHT GREEN WIRE, abbreviated as "G" in factory wiring diagrams, 18-gauge, 10-foot length:
$ 16.95

HCP1327SET25 Aftermarket GXL SOLID LIGHT GREEN WIRE, abbreviated as "G" in factory wiring diagrams, 18-gauge, 25-foot length:
$ 29.95



HCP1326 Aftermarket GXL SOLID MEDIUM GREEN WIRE, abbreviated as "G" in factory wiring diagrams, 18-gauge. Sold per foot:
$ 1.95

HCP1326SET5 Aftermarket GXL SOLID MEDIUM GREEN WIRE, abbreviated as "G" in factory wiring diagrams, 18-gauge, 5-foot length:
$ 8.95

HCP1326SET10 Aftermarket GXL SOLID MEDIUM GREEN WIRE, abbreviated as "G" in factory wiring diagrams, 18-gauge, 10-foot length:
$ 16.95

HCP1326SET25 Aftermarket GXL SOLID MEDIUM GREEN WIRE, abbreviated as "G" in factory wiring diagrams, 18-gauge, 25-foot length:
$ 29.95




HCP28868 Aftermarket GXL SOLID DARK GREEN WIRE, abbreviated as "G" in factory wiring diagrams, 18-gauge. This wire is used with the turn signal circuit on all models and is a very dark green (almost black). Sold per foot:
$ 2.95

HCP28868SET5 Aftermarket GXL SOLID DARK GREEN WIRE, abbreviated as "G" in factory wiring diagrams, 18-gauge, 5-foot length:
$ 12.95

HCP28868SET10 Aftermarket GXL SOLID DARK GREEN WIRE, abbreviated as "G" in factory wiring diagrams, 18-gauge, 10-foot length:
$ 19.95

HCP28868SET25 Aftermarket GXL SOLID DARK GREEN WIRE, abbreviated as "G" in factory wiring diagrams, 18-gauge, 25-foot length:
$ 39.95




HCP26178 Aftermarket GXL SOLID DARK GREEN WIRE, abbreviated as "G" in factory wiring diagrams, 16-gauge. This wire is used with the headlight circuit on models with analog gauges. Sold per foot:
$ 2.95

HCP26178SET5 Aftermarket GXL SOLID DARK GREEN WIRE, abbreviated as "G" in factory wiring diagrams, 16-gauge, 5-foot length:
$ 12.95

HCP26178SET10 Aftermarket GXL SOLID DARK GREEN WIRE, abbreviated as "G" in factory wiring diagrams, 16-gauge, 10-foot length:
$ 19.95

HCP26178SET25 Aftermarket GXL SOLID DARK GREEN WIRE, abbreviated as "G" in factory wiring diagrams, 16-gauge, 25-foot length:
$ 39.95




HCP12942 Aftermarket GPT SOLID GREEN CLOTH-COVERED WIRE, abbreviated as "G" in factory wiring diagrams, 18-gauge cloth-covered. This wire is used only on the alternator rotor brushes lead harness on all bikes except XJ1100 models. Use with the HCP14154 harness sheathing. Sold per foot:
$ 2.95

HCP12942SET5 Aftermarket GPT SOLID GREEN CLOTH-COVERED WIRE, abbreviated as "G" in factory wiring diagrams, 18-gauge cloth-covered, 5-foot length:
$ 12.95

HCP12942SET10 Aftermarket GPT SOLID GREEN CLOTH-COVERED WIRE, abbreviated as "G" in factory wiring diagrams, 18-gauge cloth-covered, 10-foot length:
$ 19.95



Green Tracer Wire:

Used for the clutch hand lever position switch circuit only, the green wire with a yellow tracer stripe was originally 20-gauge wire, and is only offered as an 18-gauge replacement wire.

On some models, there is also a green wire with a blue tracer stripe used in the kickstand switch circuit; we do not have that color combination available, and offer the Green with Red Tracer stripe wire as a substitute.

As noted above, any original Green (G) colored wire could be either a Light Green or a Medium Green color. The Light or Medium Green colored tracer wire that we offer below may or may not match your original "green" colored harness wire exactly.


HCP12842 Aftermarket GXL LIGHT GREEN with RED TRACER STRIPE WIRE, abbreviated as "G/R" in factory wiring diagrams, 18-gauge. Sold per foot:
$ 1.95

HCP12842SET5 Aftermarket GXL LIGHT GREEN with RED TRACER STRIPE WIRE, abbreviated as "G/R" in factory wiring diagrams, 18-gauge, 5-foot length:
$ 8.95

HCP12842SET10 Aftermarket GXL LIGHT GREEN with RED TRACER STRIPE WIRE, abbreviated as "G/R" in factory wiring diagrams, 18-gauge, 10-foot length:
$ 16.95

HCP12842SET25 Aftermarket GXL LIGHT GREEN with RED TRACER STRIPE WIRE, abbreviated as "G/R" in factory wiring diagrams, 18-gauge, 25-foot length:
$ 29.95



HCP9534 Aftermarket GXL MEDIUM GREEN with RED TRACER STRIPE WIRE, abbreviated as "G/R" in factory wiring diagrams, 18-gauge. Sold per foot:
$ 1.95

HCP9534SET5 Aftermarket GXL MEDIUM GREEN with RED TRACER STRIPE WIRE, abbreviated as "G/R" in factory wiring diagrams, 18-gauge, 5-foot length:
$ 8.95

HCP9534SET10 Aftermarket GXL MEDIUM GREEN with RED TRACER STRIPE WIRE, abbreviated as "G/R" in factory wiring diagrams, 18-gauge, 10-foot length:
$ 16.95

HCP9534SET25 Aftermarket GXL MEDIUM GREEN with RED TRACER STRIPE WIRE, abbreviated as "G/R" in factory wiring diagrams, 18-gauge, 25-foot length:
$ 29.95



HCP26179 Aftermarket GXL DARK GREEN with RED TRACER STRIPE WIRE, abbreviated as "G/R" in factory wiring diagrams, 16-gauge. This wire is used with the headlight circuit on models with a "computer" dash. Sold per foot:
$ 2.95

HCP26179SET5 Aftermarket GXL DARK GREEN with RED TRACER STRIPE WIRE, abbreviated as "G/R" in factory wiring diagrams, 16-gauge, 5-foot length:
$ 12.95

HCP26179SET10 Aftermarket GXL DARK GREEN with RED TRACER STRIPE WIRE, abbreviated as "G/R" in factory wiring diagrams, 16-gauge, 10-foot length:
$ 19.95

HCP26179SET25 Aftermarket GXL DARK GREEN with RED TRACER STRIPE WIRE, abbreviated as "G/R" in factory wiring diagrams, 16-gauge, 25-foot length:
$ 39.95



HCP1338 Aftermarket GXL LIGHT GREEN with YELLOW TRACER STRIPE WIRE, abbreviated as "G/Y" in factory wiring diagrams, 18-gauge. Sold per foot:
$ 1.95

HCP1338SET5 Aftermarket GXL LIGHT GREEN with YELLOW TRACER STRIPE WIRE, abbreviated as "G/Y" in factory wiring diagrams, 18-gauge, 5-foot length:
$ 8.95

HCP1338SET10 Aftermarket GXL LIGHT GREEN with YELLOW TRACER STRIPE WIRE, abbreviated as "G/Y" in factory wiring diagrams, 18-gauge, 10-foot length:
$ 16.95

HCP1338SET25 Aftermarket GXL LIGHT GREEN with YELLOW TRACER STRIPE WIRE, abbreviated as "G/Y" in factory wiring diagrams, 18-gauge, 25-foot length:
$ 29.95



Solid Grey (Gy) Wire:

Used from the pick-up coils to the TCI, and from the TCI to the ignition coils, this wire was originally 18-gauge.

NOTE: when reading a factory wire diagram, be careful not to confuse the abbreviation for this Solid Grey wire (Gy) with the abbreviation for a Green wire with a yellow tracer stripe (G/Y)!

HCP1328 Aftermarket GXL SOLID GREY WIRE, abbreviated as "Gy" in factory wiring diagrams, 18-gauge. Sold per foot:
$ 1.95

HCP1328SET5 Aftermarket GXL SOLID GREY WIRE, abbreviated as "Gy" in factory wiring diagrams, 18-gauge, 5-foot length:
$ 8.95

HCP1328SET10 Aftermarket GXL SOLID GREY WIRE, abbreviated as "Gy" in factory wiring diagrams, 18-gauge, 10-foot length:
$ 16.95

HCP1328SET25 Aftermarket GXL SOLID GREY WIRE, abbreviated as "Gy" in factory wiring diagrams, 18-gauge, 25-foot length:
$ 29.95



Solid Orange (O) Wire:

Used from the pick-up coils to the TCI, and from the TCI to the ignition coils, this wire was originally 18-gauge.


HCP1330 Aftermarket GXL SOLID ORANGE WIRE, abbreviated as "O" in factory wiring diagrams, 18-gauge. Sold per foot:
$ 1.95

HCP1330SET5 Aftermarket GXL SOLID ORANGE WIRE, abbreviated as "O" in factory wiring diagrams, 18-gauge, 5-foot length:
$ 8.95

HCP1330SET10 Aftermarket GXL SOLID ORANGE WIRE, abbreviated as "O" in factory wiring diagrams, 18-gauge, 10-foot length:
$ 16.95

HCP1330SET25 Aftermarket GXL SOLID ORANGE WIRE, abbreviated as "O" in factory wiring diagrams, 18-gauge, 25-foot length:
$ 29.95



Solid Pink (P) Wire:

Used for the horn wiring, this wire was originally 18-gauge.


HCP1331 Aftermarket GXL SOLID PINK WIRE, abbreviated as "P" in factory wiring diagrams, 18-gauge. Sold per foot:
$ 1.95

HCP1331SET5 Aftermarket GXL SOLID PINK WIRE, abbreviated as "P" in factory wiring diagrams, 18-gauge, 5-foot length:
$ 8.95

HCP1331SET10 Aftermarket GXL SOLID PINK WIRE, abbreviated as "P" in factory wiring diagrams, 18-gauge, 10-foot length:
$ 16.95

HCP1331SET25 Aftermarket GXL SOLID PINK WIRE, abbreviated as "P" in factory wiring diagrams, 18-gauge, 25-foot length:
$ 29.95



Solid Red (R) Wire:

Used for the main harness power feed off of the battery positive cable or the solenoid, the solid red wire feeds thru the fusebox and the ignition switch, and also runs to the voltage regulator/rectifier unit. This wire was originally 14-gauge and you should never use any smaller size. We also offer it in a larger 12-gauge size.


HCP9536 Aftermarket GXL SOLID RED WIRE, abbreviated as "R" in factory wiring diagrams, 14-gauge. Sold per foot:
$ 2.95

HCP9536SET5 Aftermarket GXL SOLID RED WIRE, abbreviated as "R" in factory wiring diagrams, 14-gauge, 5-foot length:
$ 12.95

HCP9536SET10 Aftermarket GXL SOLID RED WIRE, abbreviated as "R" in factory wiring diagrams, 14-gauge, 10-foot length:
$ 19.95

HCP9536SET25 Aftermarket GXL SOLID RED WIRE, abbreviated as "R" in factory wiring diagrams, 14-gauge, 25-foot length:
$ 39.95



HCP389 Aftermarket GXL SOLID RED WIRE, abbreviated as "R" in factory wiring diagrams, 12-gauge. Sold per foot:
$ 2.95

HCP389SET5 Aftermarket GXL SOLID RED WIRE, abbreviated as "R" in factory wiring diagrams, 12-gauge, 5-foot length:
$ 128.95

HCP389SET10 Aftermarket GXL SOLID RED WIRE, abbreviated as "R" in factory wiring diagrams, 12-gauge, 10-foot length:
$ 19.95

HCP389SET25 Aftermarket GXL SOLID RED WIRE, abbreviated as "R" in factory wiring diagrams, 12-gauge, 25-foot length:
$ 39.95



Red Tracer Wire:

Used in a variety of places on the harness, red wires with tracer colors are the power feeds for various circuits, including many of the safety relays, the ignition coils, the starter solenoid, and other devices.

NOTE: many of the original wires on your harness will be 20-gauge. We do not offer 20-gauge wire and recommend that you substitute the slightly larger 18-gauge wire in place of it. The Red with yellow tracer stripe wire (R/Y) in most harness was originally 18-gauge, and we only have this color wire available in a larger 16-gauge replacement.


HCP1342 Aftermarket GXL RED with BLACK TRACER STRIPE WIRE, abbreviated as "R/B" in factory wiring diagrams, 18-gauge. Sold per foot:
$ 1.95

HCP1342SET5 Aftermarket GXL RED with BLACK TRACER STRIPE WIRE, abbreviated as "R/B" in factory wiring diagrams, 18-gauge, 5-foot length:
$ 8.95

HCP1342SET10 Aftermarket GXL RED with BLACK TRACER STRIPE WIRE, abbreviated as "R/B" in factory wiring diagrams, 18-gauge, 10-foot length:
$ 16.95

HCP1342SET25 Aftermarket GXL RED with BLACK TRACER STRIPE WIRE, abbreviated as "R/B" in factory wiring diagrams, 18-gauge, 25-foot length:
$ 29.95



HCP387 Aftermarket GXL RED with WHITE TRACER STRIPE WIRE, abbreviated as "R/W" in factory wiring diagrams, 18-gauge. Sold per foot:
$ 1.95

HCP387SET5 Aftermarket GXL RED with WHITE TRACER STRIPE WIRE, abbreviated as "R/W" in factory wiring diagrams, 18-gauge, 5-foot length:
$ 8.95

HCP387SET10 Aftermarket GXL RED with WHITE TRACER STRIPE WIRE, abbreviated as "R/W" in factory wiring diagrams, 18-gauge, 10-foot length:
$ 16.95

HCP387SET25 Aftermarket GXL RED with WHITE TRACER STRIPE WIRE, abbreviated as "R/W" in factory wiring diagrams, 18-gauge, 25-foot length:
$ 29.95



HCP390 Aftermarket GXL RED with YELLOW TRACER STRIPE WIRE, abbreviated as "R/Y" in factory wiring diagrams, 16-gauge. Sold per foot:
$ 2.95

HCP390SET5 Aftermarket GXL RED with YELLOW TRACER STRIPE WIRE, abbreviated as "R/Y" in factory wiring diagrams, 16-gauge, 5-foot length:
$ 12.95

HCP390SET10 Aftermarket GXL RED with YELLOW TRACER STRIPE WIRE, abbreviated as "R/Y" in factory wiring diagrams, 16-gauge, 10-foot length:
$ 19.95

HCP390SET25 Aftermarket GXL RED with YELLOW TRACER STRIPE WIRE, abbreviated as "R/Y" in factory wiring diagrams, 16-gauge, 25-foot length:
$ 39.95



Solid White Wire:

Used for the alternator stator, regulator/rectifier, and the headlight relay and diode wiring, this wire was originally either 20-gauge (use 18-gauge instead) or 16-gauge (alternator wiring). Note that the solid white wires coming out of the stator itself is a braided-cloth covered wire, and the standard plastic insulated wire that we offer should not be substituted for the cloth-covered wire.


HCP1333 Aftermarket GXL SOLID WHITE WIRE, abbreviated as "W" in factory wiring diagrams, 18-gauge. Sold per foot:
$ 1.95

HCP1333SET5 Aftermarket GXL SOLID WHITE WIRE, abbreviated as "W" in factory wiring diagrams, 18-gauge, 5-foot length:
$ 8.95

HCP1333SET10 Aftermarket GXL SOLID WHITE WIRE, abbreviated as "W" in factory wiring diagrams, 18-gauge, 10-foot length:
$ 16.95

HCP1333SET25 Aftermarket GXL SOLID WHITE WIRE, abbreviated as "W" in factory wiring diagrams, 18-gauge, 25-foot length:
$ 29.95



HCP9540 Aftermarket GXL SOLID WHITE WIRE, abbreviated as "W" in factory wiring diagrams, 16-gauge. Sold per foot:
$ 2.95

HCP9540SET5 Aftermarket GXL SOLID WHITE WIRE, abbreviated as "W" in factory wiring diagrams, 16-gauge, 5-foot length:
$ 12.95

HCP9540SET10 Aftermarket GXL SOLID WHITE WIRE, abbreviated as "W" in factory wiring diagrams, 16-gauge, 10-foot length:
$ 19.95

HCP9540SET25 Aftermarket GXL SOLID WHITE WIRE, abbreviated as "W" in factory wiring diagrams, 16-gauge, 25-foot length:
$ 39.95



HCP12941 Aftermarket GPT SOLID WHITE CLOTH-COVERED WIRE, abbreviated as "W" in factory wiring diagrams, 18-gauge cloth-covered. This wire is used on the alternator stator lead harness only on all models. Sold per foot:
$ 2.95

HCP12941SET5 Aftermarket GPT SOLID WHITE CLOTH-COVERED WIRE, abbreviated as "W" in factory wiring diagrams, 18-gauge cloth-covered, 5-foot length:
$ 12.95

HCP12941SET10 Aftermarket GPT SOLID WHITE CLOTH-COVERED WIRE, abbreviated as "WB" in factory wiring diagrams, 18-gauge cloth-covered, 10-foot length:
$ 19.95

HCP12941SET25 Aftermarket GPT SOLID WHITE CLOTH-COVERED WIRE, abbreviated as "W" in factory wiring diagrams, 18-gauge cloth-covered, 25-foot length:
$ 39.95



White Tracer Wire:

Used in a variety of sensing or lighting circuits, most o these wires were originally a 20-gauge wire, and are only offered as an 18-gauge replacement wire.


HCP1343 Aftermarket GXL WHITE with BLACK TRACER STRIPE WIRE, abbreviated as "W/B" in factory wiring diagrams, 18-gauge. Sold per foot:
$ 1.95

HCP1343SET5 Aftermarket GXL WHITE with BLACK TRACER STRIPE WIRE, abbreviated as "W/B" in factory wiring diagrams, 18-gauge, 5-foot length:
$ 8.95

HCP1343SET10 Aftermarket GXL WHITE with BLACK TRACER STRIPE WIRE, abbreviated as "W/B" in factory wiring diagrams, 18-gauge, 10-foot length:
$ 16.95

HCP1343SET25 Aftermarket GXL WHITE with BLACK TRACER STRIPE WIRE, abbreviated as "W/B" in factory wiring diagrams, 18-gauge, 25-foot length:
$ 29.95



HCP9542 Aftermarket GXL WHITE with BLUE TRACER STRIPE WIRE, abbreviated as "W/L" in factory wiring diagrams, 18-gauge. Sold per foot:
$ 1.95

HCP9542SET5 Aftermarket GXL WHITE with BLUE TRACER STRIPE WIRE, abbreviated as "W/L" in factory wiring diagrams, 18-gauge, 5-foot length:
$ 8.95

HCP9542SET10 Aftermarket GXL WHITE with BLUE TRACER STRIPE WIRE, abbreviated as "W/L" in factory wiring diagrams, 18-gauge, 10-foot length:
$ 16.95

HCP9542SET25 Aftermarket GXL WHITE with BLUE TRACER STRIPE WIRE, abbreviated as "W/L" in factory wiring diagrams, 18-gauge, 25-foot length:
$ 29.95



HCP1344 Aftermarket GXL WHITE with DARK GREEN TRACER STRIPE WIRE, abbreviated as "W/G" in factory wiring diagrams, 18-gauge. Sold per foot:
$ 1.95

HCP1344SET5 Aftermarket GXL WHITE with DARK GREEN TRACER STRIPE WIRE, abbreviated as "W/G" in factory wiring diagrams, 18-gauge, 5-foot length:
$ 8.95

HCP1344SET10 Aftermarket GXL WHITE with DARK GREEN TRACER STRIPE WIRE, abbreviated as "W/G" in factory wiring diagrams, 18-gauge, 10-foot length:
$ 16.95

HCP1344SET25 Aftermarket GXL WHITE with DARK GREEN TRACER STRIPE WIRE, abbreviated as "W/G" in factory wiring diagrams, 18-gauge, 25-foot length:
$ 29.95



HCP1345 Aftermarket GXL WHITE with RED TRACER STRIPE WIRE, abbreviated as "W/R" in factory wiring diagrams, 18-gauge. Sold per foot:
$ 1.95

HCP1345SET5 Aftermarket GXL WHITE with RED TRACER STRIPE WIRE, abbreviated as "W/R" in factory wiring diagrams, 18-gauge, 5-foot length:
$ 8.95

HCP1345SET10 Aftermarket GXL WHITE with RED TRACER STRIPE WIRE, abbreviated as "W/R" in factory wiring diagrams, 18-gauge, 10-foot length:
$ 16.95

HCP1345SET25 Aftermarket GXL WHITE with RED TRACER STRIPE WIRE, abbreviated as "W/R" in factory wiring diagrams, 18-gauge, 25-foot length:
$ 29.95



Solid Yellow (Y) Wire:

Used for the rear brake light and, on some models, the headlight wiring, this wire was originally either 20-gauge (use 18-gauge instead) or 16-gauge. Note that some models used a Yellow wire with a green tracer stripe (Y/G) for the headlight circuit (instead of a solid yellow wire).


HCP1334 Aftermarket GXL SOLID YELLOW WIRE, abbreviated as "Y" in factory wiring diagrams, 18-gauge. Sold per foot:
$ 1.95

HCP1334SET5 Aftermarket GXL SOLID YELLOW WIRE, abbreviated as "Y" in factory wiring diagrams, 18-gauge, 5-foot length:
$ 8.95

HCP1334SET10 Aftermarket GXL SOLID YELLOW WIRE, abbreviated as "Y" in factory wiring diagrams, 18-gauge, 10-foot length:
$ 16.95

HCP1334SET25 Aftermarket GXL SOLID YELLOW WIRE, abbreviated as "Y" in factory wiring diagrams, 18-gauge, 25-foot length:
$ 29.95



HCP9544 Aftermarket GXL SOLID YELLOW WIRE, abbreviated as "Y" in factory wiring diagrams, 16-gauge. This wire is used in the headlight circuit. Sold per foot:
$ 2.95

HCP9544SET5 Aftermarket GXL SOLID YELLOW WIRE, abbreviated as "Y" in factory wiring diagrams, 16-gauge, 5-foot length:
$ 12.95

HCP9544SET10 Aftermarket GXL SOLID YELLOW WIRE, abbreviated as "Y" in factory wiring diagrams, 16-gauge, 10-foot length:
$ 19.95

HCP9544SET25 Aftermarket GXL SOLID YELLOW WIRE, abbreviated as "Y" in factory wiring diagrams, 16-gauge, 25-foot length:
$ 39.95



Yellow Tracer Wire:

Used for the turn signal flasher and flasher canceller, and on some models, the headlight wiring, this wire was originally either 20-gauge (use 18-gauge instead) or 18-gauge. Note that some models used a Solid Yellow wire for the headlight circuit (instead of a yellow with green tracer stripe wire).

NOTE: where used, most original models use a dark green tracer stripe on these yellow wires; our replacement wire has a light green tracer stripe instead.

NOTE: where used, most original models use a red tracer stripe on these yellow wires; our replacement wire has an orange tracer stripe instead. The original yellow with red tracer wires were 18-gauge; the only replacement we have available is in a thicker 16-gauge wire.



HCP8557 Aftermarket GXL YELLOW with LIGHT GREEN TRACER STRIPE WIRE, abbreviated as "Y/G" in factory wiring diagrams, 18-gauge. Sold per foot:
$ 1.95

HCP8557SET5 Aftermarket GXL YELLOW with LIGHT GREEN TRACER STRIPE WIRE, abbreviated as "Y/G" in factory wiring diagrams, 18-gauge, 5-foot length:
$ 8.95

HCP8557SET10 Aftermarket GXL YELLOW with LIGHT GREEN TRACER STRIPE WIRE, abbreviated as "Y/G" in factory wiring diagrams, 18-gauge, 10-foot length:
$ 16.95

HCP8557SET25 Aftermarket GXL YELLOW with LIGHT GREEN TRACER STRIPE WIRE, abbreviated as "Y/G" in factory wiring diagrams, 18-gauge, 25-foot length:
$ 29.95



HCP12884 Aftermarket GXL YELLOW with ORANGE TRACER STRIPE WIRE, abbreviated as "Y/R" in factory wiring diagrams, 16-gauge. Sold per foot:
$ 2.95

HCP12884SET5 Aftermarket GXL YELLOW with ORANGE TRACER STRIPE WIRE, abbreviated as "Y/R" in factory wiring diagrams, 16-gauge, 5-foot length:
$ 12.95

HCP12884SET10 Aftermarket GXL YELLOW with ORANGE TRACER STRIPE WIRE, abbreviated as "Y/R" in factory wiring diagrams, 16-gauge, 10-foot length:
$ 19.95

HCP12884SET25 Aftermarket GXL YELLOW with ORANGE TRACER STRIPE WIRE, abbreviated as "Y/R" in factory wiring diagrams, 16-gauge, 25-foot length:
$ 39.95



HCP9546 Aftermarket GXL YELLOW with WHITE TRACER STRIPE WIRE, abbreviated as "Y/W" in factory wiring diagrams, 18-gauge. Sold per foot:
$ 1.95

HCP9546SET5 Aftermarket GXL YELLOW with WHITE TRACER STRIPE WIRE, abbreviated as "Y/W" in factory wiring diagrams, 18-gauge, 5-foot length:
$ 8.95

HCP9546SET10 Aftermarket GXL YELLOW with WHITE TRACER STRIPE WIRE, abbreviated as "Y/W" in factory wiring diagrams, 18-gauge, 10-foot length:
$ 16.95

HCP9546SET25 Aftermarket GXL YELLOW with WHITE TRACER STRIPE WIRE, abbreviated as "Y/W" in factory wiring diagrams, 18-gauge, 25-foot length:
$ 29.95



Accessory Color Wire:

Sometimes, you'll want to add electrical accessory circuits to you bike.....a cigarette lighter, heated grips, perhaps a power port for a GPS unit, etc......and in such situations, it's best to run a separate circuit, with its own unique color-coded wiring, in order to keep things neat and orderly, electrically-speaking. We offer the following unique colors (not used anywhere else on your bike) to help you safely and accurately identify any new circuits that you add.


HCP9547 Aftermarket GXL PINK with BLACK TRACER STRIPE WIRE, abbreviated P/B, 16-gauge. Sold per foot:
$ 2.95

HCP9547SET5 Aftermarket GXL PINK with BLACK TRACER STRIPE WIRE, abbreviated P/B, 16-gauge, 5-foot length:
$ 12.95

HCP9547SET10 Aftermarket GXL PINK with BLACK TRACER STRIPE WIRE, abbreviated P/B, 16-gauge, 10-foot length:
$ 19.95

HCP9547SET25 Aftermarket GXL PINK with BLACK TRACER STRIPE WIRE, abbreviated P/B, 16-gauge, 25-foot length:
$ 39.95



HCP9548 Aftermarket GXL PURPLE with WHITE TRACER STRIPE WIRE, abbreviated Pu/W, 16-gauge. Sold per foot:
$ 2.95

HCP9548SET5 Aftermarket GXL PURPLE with WHITE TRACER STRIPE WIRE, abbreviated Pu/W, 16-gauge, 5-foot length:
$ 12.95

HCP9548SET10 Aftermarket GXL PURPLE with WHITE TRACER STRIPE WIRE, abbreviated Pu/W, 16-gauge, 10-foot length:
$ 19.95

HCP9548SET25 Aftermarket GXL PURPLE with WHITE TRACER STRIPE WIRE, abbreviated Pu/W, 16-gauge, 25-foot length:
$ 39.95

 

Wire Harness Tape:

Factory wire harness bundles were taped with a black electrically-insulating protective VINYL ELECTRICAL TAPE WRAP to provide both an orderly routing of the main harness wires and for additional wire protection. We have the correct 19mm wide black, high-voltage, adhesive-backed, all-weather stretch tape to allow you to repair or re-tape your harness. NOTE: XJ750 Maxim models that used this hard-shell, plastic ribbed tubing to protect the wire bundles had the hard-shell tubing externally wrapped with this tape.

HCP12923 Aftermarket harness bundle VINYL ELECTRICAL TAPE WRAP, black, 20-foot roll.
$ 8.95

HCP13134 Aftermarket harness bundle VINYL ELECTRICAL TAPE WRAP, black, 66-foot roll, almost enough to do one complete harness.
$ 16.95

Additionally, most harnesses had a few short turns of COLORED VINYL ELECTRICAL TAPE WRAP to provide visual identification of "what connector goes where?" during harness assembly and installation. Always located just by the connector shell, about 3-4 turns of this tape was used to both tape off any vinyl sleeve and to properly identify what the connector plugged into. Used primarily at the TCI connector (from the pick-up coils) and at the various small "cube" style relays (headlight relays, sidestand safety switch relays, etc.). Since all of these harness connector shells are the same style and type (4-position, horizontally oriented 2-over-2), this small tape wrap served as a way of indicating which of these many identical connectors went to which component.

HCP13130 Aftermarket harness bundle YELLOW VINYL ELECTRICAL TAPE WRAP, 20-foot roll. Used by the pick-up coil harness connector (at the TCI) on XJ700-X and XJ750-X models, and at the headlight relay connector on all XJ550 models, all XJ650 (except Turbo) models, and all XJ750 Seca models.
$ 7.95

HCP13131 Aftermarket harness bundle RED VINYL ELECTRICAL TAPE WRAP, 20-foot roll. Used by the pick-up coil harness connector (at the TCI) on 1982-83 XJ650 Maxim models, all '81-83 XJ750 models, and all XJ700 non-X models, and at the fuel pump relay connector on all XJ650 Turbo models.
$ 7.95

HCP13132 Aftermarket harness bundle BLUE VINYL ELECTRICAL TAPE WRAP, 20-foot roll. Used by the pick-up coil harness connector (at the TCI) on all XJ550 models, at the emergency stop switch relay connector on all XJ650 Turbo models, and for the sidestand safety switch relay connector on all XJ550 models, all '82-83 XJ650 models, all XJ750 models, XJ900RK and XJ1100 models.
$ 7.95

HCP13133 Aftermarket harness bundle GREEN VINYL ELECTRICAL TAPE WRAP, 20-foot roll. Used by the pick-up coil harness connector (at the TCI) on all XJ650RJ Seca and XJ1100 models.
$ 7.95



Individual Wire Sheathing:

The main harness feed solid red wire (14-gauge) used a braided cloth-like sheathing over it to protect it from any chance of insulation breakage. Although the original material is no longer available, we offer an expandable polyester sheathing that is similar in appearance and serves the same function as the original. Sold in 1-foot lengths, more than enough for any of the main harness lead wires.

HCP12921 Aftermarket red plastic protective WIRE SHEATH, 12" length.
$ 5.95


The pick-up coil harness lead wires and the alternator rotor brush-plate lead wires inside the engine cases use a thick, black heat-resistant sleeve over their wires to protect them from both the heat and pinching when the wire exit the engine cases. XJ550 models also use this type of thermal sheath over the kickstand switch lead wires. Sold in 1-foot lengths.

HCP13326 Aftermarket black heat-resistant protective WIRE SHEATH, 12" length.
$ 5.95





Wire Harness Bundle Sheathing:

Most factory wire harness bundles were taped with a black electrically-insulating protective tape to provide both an orderly routing of the main harness wires and for additional wire protection. In addition, the two forward branches of the main harness were further protected by a smooth, flexible black WIRE HARNESS BUNDLE VINYL SHEATHING, while other models used a flexible, black ribbed WIRE HARNESS BUNDLE HARD SHELL SPLIT-TUBE SHEATHING. NOTE: some models that used the hard-shell, plastic ribbed split-tubing to protect the wire bundles were then also externally wrapped with vinyl electrical tape.


HCP14153 Aftermarket smooth, flexible black WIRE HARNESS BUNDLE VINYL SHEATHING. Slightly larger than stock size but fits and performs just fine. Used on a variety of different models, in different locations (control switch lead wires, sensor lead wires, etc.), 4.75mm internal diameter, holds two-wire lead harnesses. NOTE: wires must be routed through this sheathing before wire-end terminals are applied! Sold per foot:
$ 2.95

HCP14154 Aftermarket smooth, flexible black WIRE HARNESS BUNDLE VINYL SHEATHING. Slightly larger than stock size but fits and performs just fine. Used on a variety of different models, in different locations (control switch lead wires, sensor lead wires, etc.), 6.35mm internal diameter, holds up to five-wire lead harnesses. NOTE: wires must be routed through this sheathing before wire-end terminals are applied! This size sheath is the correct one to use when routing cloth-covered wires, such as for the alternator rotor harness. Sold per foot:
$ 2.95

HCP14155 Aftermarket smooth, flexible black WIRE HARNESS BUNDLE VINYL SHEATHING. Slightly larger than stock size but fits and performs just fine. Used on a variety of different models, in different locations (control switch lead wires, sensor lead wires, etc.), 8.00mm internal diameter, holds up to six-wire lead harnesses. NOTE: wires must be routed through this sheathing before wire-end terminals are applied! Sold per foot:
$ 2.95

HCP14156 Aftermarket smooth, flexible black WIRE HARNESS BUNDLE VINYL SHEATHING. Slightly larger than stock size but fits and performs just fine. Used on a variety of different models, in different locations (control switch lead wires, sensor lead wires, etc.), 9.50mm internal diameter, holds up to eight-wire lead harnesses. NOTE: wires must be routed through this sheathing before wire-end terminals are applied! Sold per foot:
$ 2.95

HCP14158 Aftermarket smooth, flexible black WIRE HARNESS BUNDLE VINYL SHEATHING. Slightly larger than stock size but fits and performs just fine. Used on a variety of different models, in different locations (control switch lead wires, sensor lead wires, etc.), 12.70mm internal diameter, holds up to fourteen-wire lead harnesses. NOTE: wires must be routed through this sheathing before wire-end terminals are applied! Sold per foot:
$ 3.95

HCP12945 Aftermarket smooth, flexible black WIRE HARNESS BUNDLE VINYL SHEATHING. Slightly smaller (16mm ID) than stock size but fits and performs just fine. Used on all XJ550 and XJ650 (except Turbo) main forward harness branch "arms", approximately 2-feet per branch. Holds up to approximately 25 wires. NOTE: wires must be routed through this sheathing before wire-end terminals are applied! Sold per foot:
$ 4.95

HCP12946 Aftermarket smooth, flexible black WIRE HARNESS BUNDLE VINYL SHEATHING. Slightly smaller (19mm ID) than stock size but fits and performs just fine. Used on all XJ750 Seca models main forward harness branch "arms", approximately 2-feet per branch. Holds up to approximately 33 wires. NOTE: wires must be routed through this sheathing before wire-end terminals are applied! Sold per foot:
$ 5.95

HCP14162 Aftermarket smooth, flexible black WIRE HARNESS BUNDLE VINYL SHEATHING. Large size for custom harness construction, 22mm ID. Holds up to approximately 48 wires. NOTE: wires must be routed through this sheathing before wire-end terminals are applied! Sold per foot:
$ 6.95

HCP14163 Aftermarket smooth, flexible black WIRE HARNESS BUNDLE VINYL SHEATHING. Large size for custom harness construction, 25mm ID. Holds up to approximately 58 wires. NOTE: wires must be routed through this sheathing before wire-end terminals are applied! Sold per foot:
$ 7.95





HCP13149 Aftermarket flexible, black ribbed WIRE HARNESS BUNDLE HARD SHELL SPLIT-TUBE SHEATHING. Slightly larger than stock size but fits and performs just fine. "Split" tube design allows completed wire bundle to be inserted into the tube even while the harness is fully assembled. Used on all 1982-3 XJ750 Maxim and Midnight Maxim models on the main harness bundle forward branch arms (approximately 2-feet per arm). Sold per foot:
$ 4.95

HCP12924 Aftermarket harness bundle flexible, black ribbed WIRE HARNESS BUNDLE HARD SHELL SPLIT-TUBE SHEATHING. Slightly larger than stock size but fits and performs just fine. "Split" tube design allows completed wire bundle to be inserted into the tube even while the harness is fully assembled. Use approximately 2-feet on all XJ700 non-X models, and approximately 1-foot on all 1985-86 XJ700 and XJ750-X models on the main harness bundle forward branch arm, just before the harness enters the headlight housing. Sold per foot:
$ 4.95

 

WIRE-END TERMINALS and TERMINAL SHEATHS:

The WIRE-END TERMINALS are the brass (or, for added corrosion resistance, tin-plated brass) metal ends that are used to actually "join" wires together at their mating point (usually within a plastic connector block or "shell") These terminals come in a variety of original shapes, styles, and sizes to allow you to properly replace the ones used on your harness, and are of the "OEM" (known as "open-arm" or "open barrel") style that allows both soldering and crimping of both the wire core and the wire insulation to the terminal, providing the ultimate in strain relief, security, and corrosion resistance.

NOTE: these OEM style terminals require a special crimping tool to properly attach the terminal to the stripped wire end; regular "chain-store" terminal crimpers (for "closed barrel" style terminals) are designed to be used with those "chain-store" style terminals and will not work properly (nor will, for heaven's sake, pliers!) with these OEM style terminals! The crimping process and specialized tool required can be visualized here:

http://www.xj4ever.com/crimping my style.pdf


Additionally, it is strongly advised that you obtain a few extra terminals beyond whatever number you need for your project. It is very easy to burst the clamping arms on these open-barrel style terminals if you are inexperienced at using these types of terminals and their specialty crimping tool and procedures.

The proper OEM "open-barrel" style crimping tools can be found further below in the "Electrical Tools" section, as can the terminal de-pinning tools (special flat-blade "picks" that are used to extract a terminal that has been inserted and locked into a connector shell).


The ends of all wires are terminated either into a "device" (the oil sending unit, the brake switch unit, etc.) or with a metal WIRE-END TERMINAL. These metal terminals are normally made of solid brass, although some tin-plated brass terminals can also be found (and either type performs just as well as the other). End terminals come in a variety of different shapes, sizes, and styles, such as FLAT BLADES, ROUND PINS, RINGS or SPLIT-RINGS, and BULLETS are the most common. And of course, there are MALE and FEMALE versions of each terminal, and some types also are available in different sizes (small, medium, or large Flat Blade End Terminals, for example or configurations, such as the single, double, or triple female Bullet End Terminals.

Wire-end terminal PROTECTIVE SHEATHS are used primarily with the round Bullet Wire-end Terminals, and usually on the female bullet terminal only. Some of the 90-degree end terminals (primarily at the horns) use a flexible black rubber sheath or cover to protect the bare end terminal.


We offer both the original style end terminals, as well as some aftermarket, general-wiring style of BUTT CONNECTORS and standard FLAT BLADE WIRE-END TERMINALS for splicing or adding in non-stock connect/dis-connect features into your harness.

ALL of our original-style terminals are the correct metric size terminals like the types used originally on your harness, and thus will properly fit (and lock into) the matching male or female terminal "mate" on your original harness, and will also fit and lock properly into your original plastic connector shells. Please note that there are a wide variety of wire-end terminal types available in the marketplace, and most "USA" (inch fractional sizes) will not mate with original terminals, nor do they have the correct retention tab needed to lock into original connector shells!

On your original harness, each specific wire for a particular circuit not only used a designated size and color wire, but at least one end is terminated by a specific style and type of Wire-End Terminal.



Original type Small Straight Flat Spade Wire-End Terminals:

These original style "thin" straight flat blade terminals are tiny little things, and are approximately 3mm wide (side-to-side). Flat blade terminals are also referred to as "flat spade" or "tab" style terminals. All of these "open-barrel" style terminals are designed to be both crimped onto the wire insulation and to the bare wire.


HCP9362BR1418 Aftermarket original style "thin" straight MALE SMALL BRASS FLAT BLADE WIRE-END TERMINAL, correct style solid brass terminal features a retention tab for insertion and positive locking into their connector shell. Accepts 14-18 gauge wires. Each:
$ 1.25

HCP9362BR1822 Aftermarket original style "thin" straight MALE SMALL BRASS FLAT BLADE WIRE-END TERMINAL, correct style solid brass terminal features a retention tab for insertion and positive locking into their connector shell. Accepts 18-22 gauge wires. Each:
$ 1.25

HCP9362TP1622 Aftermarket original style "thin" straight MALE SMALL BRASS FLAT BLADE WIRE-END TERMINAL, correct style tin-plated solid brass terminal features a retention tab for insertion and positive locking into their connector shell. The tin plating gives an additional level of corrosion resistance to the brass terminal. Accepts 16-22 gauge wires. Each:
$ 1.25



HCP9363BRD1418 Aftermarket original style "thin" straight FEMALE SMALL BRASS FLAT BLADE WIRE-END TERMINAL, correct style solid brass terminal features a retention tab for insertion and positive locking into their connector shell. These terminals feature the original style locking "dimple" which gives an additional level of terminal-to-terminal locking ability when mated with its male counterpart. Accepts 14-18 gauge wires. Each:
$ 1.25

HCP9363BR1822 Aftermarket original style "thin" straight FEMALE SMALL BRASS FLAT BLADE WIRE-END TERMINAL, correct style solid brass terminal features a retention tab for insertion and positive locking into their connector shell. Accepts 18-22 gauge wires. NOTE: will not fit any of the HCP9337xxxx series shells. Each:
$ 1.25


HCP9363BRD1822 Aftermarket original style "thin" straight FEMALE SMALL BRASS FLAT BLADE WIRE-END TERMINAL, correct style solid brass terminal features a retention tab for insertion and positive locking into their connector shell. These terminals feature the original style locking "dimple" which gives an additional level of terminal-to-terminal locking ability when mated with its male counterpart. Accepts 18-22 gauge wires. Each:
$ 1.25

HCP9363TP1622 Aftermarket original style "thin" straight FEMALE SMALL BRASS FLAT BLADE WIRE-END TERMINAL, correct style tin-plated solid brass terminal features a retention tab for insertion and positive locking into their connector shell. The tin plating gives an additional level of corrosion resistance to the brass terminal. Accepts 16-22 gauge wires. NOTE: for use only with the HCP9359MFWHTWE male connector shell; will not fit any of the HCP9337xxxx series shells. Each:
$ 1.25



HCP28001 Aftermarket "trapezoid-shaped" FEMALE SMALL BRASS FLAT BLADE WIRE-END TERMINAL, correct style tin-plated solid brass terminal features a retention tab for insertion and positive locking into their connector shell. The tin plating gives an additional level of corrosion resistance to the brass terminal. Accepts 16-22 gauge wires. NOTE: this terminal only fits the original 9-place white connector shell used on all FJ600, XJ700, and the XJ750-X models at the large "consolidated" turn signal flasher and starting circuit safety relay assembly (located under the gas tank). Each:
$ 1.50



Original type Medium Straight Flat Blade Wire-End Terminals:

These original style, "medium-width" straight flat spade terminals are the most common style of end terminal used on these bikes, and are slightly over 6mm wide (side-to-side). Flat blade terminals are also referred to as "flat spade" or "tab" style terminals. All of these "open-barrel" style terminals are designed to be both crimped onto the wire insulation and to the bare wire.


HCP9360BR1418 Aftermarket "medium-width" straight MALE MEDIUM BRASS FLAT BLADE WIRE-END TERMINAL, correct style solid brass terminal features a retention tab for insertion and positive locking into their connector shell. Accepts 14-18 gauge wires. Each:
$ 1.95



HCP9361BR1418 Aftermarket "medium-width" straight FEMALE MEDIUM BRASS FLAT BLADE WIRE-END TERMINAL, correct style solid brass terminal features a retention tab for insertion and positive locking into their connector shell. Accepts 14-18 gauge wires. Each:
$ 1.95

HCP9361TPDW1418 Aftermarket "medium-width" straight FEMALE MEDIUM TIN-PLATED BRASS FLAT BLADE WIRE-END TERMINAL, correct style tin-plated solid brass terminal features a retention tab for insertion and positive locking into their connector shell. Slightly wider than the stock terminal, but still fits the mating male terminal (and the connector shell) properly. The tin plating gives an additional level of corrosion resistance to the brass terminal. Accepts 14-18 gauge wires. Each:
$ 1.95



Medium Flat Blade Terminal Protective Covers:

HCP9325 Aftermarket original style, "medium-width" straight FEMALE FLAT-BLADE STYLE WIRE-END TERMINAL PROTECTIVE SHEATH, correct size and length transparent sheath fits the HCP9361xx series of female wire-end terminals. Each:
$ 1.25



Original type Large Straight Flat Blade Wire-End Terminals:

NOTE: these original style "large" straight flat spade terminals are used only on the main harness feed wire from the positive battery cable (or solenoid) lead pigtail, and are slightly over 6mm wide (side-to-side). Flat blade terminals are also referred to as "flat spade" or "tab" style terminals. All of these "open-barrel" style terminals are designed to be both crimped onto the wire insulation and to the bare wire.


HCP9371BR1418 Aftermarket original style "large" straight brass MALE LARGE FLAT BLADE TERMINAL. Used only within the main battery lead female connector shell HCP12837FMxx on all models except XJ1100. Each:
$ 1.25

HCP12898BR1418 Aftermarket original style "large" straight brass FEMALE LARGE FLAT BLADE TERMINAL. Used only within the main battery lead male connector shell HCP12837MFxx on all models except XJ1100. Each:
$ 1.25



Original type 90-Degree Flat Blade "Flag" Wire-End Terminals:

These original style "flag" terminals make a 90-degree bend to the wire direction, and are normally used on the horn lead wires, inside the flasher relay connector shell, and inside some styles of the headlight plug connector shell. All of these "open-barrel" style terminals are designed to be both crimped onto the wire insulation and to the bare wire.


HCP9370BR1418 Aftermarket "medium-width" 90-degree FEMALE MEDIUM BRASS FLAT BLADE WIRE-END TERMINAL, correct style solid brass terminal features a retention tab for insertion and positive locking into their connector shell. Accepts 14-18 gauge wires. Each:
$ 1.75



Original type Round-Pin Wire-End Terminals:

NOTE: it is easy to confuse these round pin wire-end terminals with the similar "bullet" terminals listed elsewhere. Round Pin Wire-End Terminals are always used inside a hard plastic connector shell, while the "bullet" style terminals are never inserted into a hard-shell connector body, and are instead placed within a soft, flexible, clear plastic sheath. All of these "open-barrel" style terminals are designed to be both crimped onto the wire insulation and to the bare wire.

NOTE: we'll attempt a bit of clarity here, as we realize it's easy to get "in the weeds" over these different types of "round-pin" terminals.

There were originally 2 different suppliers to Yamaha (and probably other Japanese motorcycle builders) of shells (and their matching terminals) which used "round-pin" terminals......note that about 80% of harness connector shells and their terminals are of the "flat blade" (in varying widths) style, and for the most part (but not absolutely!), such terminals and shells are both readily available and interchangeable.

The rest of the hard plastic connector shells are of the less-common "round pin" style, and these types of shells/terminals come in two different flavors (manufacturers), and neither their shells nor their terminals are interchangeable. These 2 suppliers are Yazaki and Mitsubishi.

Yazaki shells and terminals are much more common on the harnesses, and luckily, there are reproductions available of those shells. However, the repro Yazaki shells....while they will physically mate up with an original Yazaki shell...use unique terminals which will not interchange into original Yazaki shells (and vice-versa: original Yazaki terminals won't fit into the repro shells).

The other type of "round pin" terminals and shells used on these era bike harnesses were made by Mitsubishi Electric, and were imprinted "SJD" on the terminal and this identifier was also cast into the plastic connector shell itself (note: male shells had the "SJD" cast onto the front "face' of the shell, and thus it's pretty easy to see.....small, but readable. Female shells have the SJD marking cast inside the terminal cavity, and thus it may be very difficult to see. Of course, if the male shell has SJD cast into it, then its matching female shell is also made by Mitsubishi, whether you can see the marking or not). Mitsubishi got out of the motorcycle terminal and shell business quite some time ago, and thus original shells and terminals are hard to come by. These Mitsubishi "SJD" shells were mainly used on the control switch harness connections and on XJ700 gauge cluster harnesses, and are 6-place shells with a "divider" or separator bar internal to shell that "divides" the shell into a 4-place and a 2-place section.

The HCP28300TP and HCP28301TP terminals below are the correct terminals which will fit original "SJD" shells only. We do not currently have any original or reproduction "SJD" style shells, so these terminals can only be used to replace missing or damaged terminals used with your original SJD shells.

The HCP24540TP and HCP24541TP terminals below are the correct terminals for the "repro" Yazaki round-pin style shells mentioned in their description . They will not fit the original Yazaki shells.

The HCP9326TP and HCP9327TP terminals below are the correct terminals for the specific shells mentioned in their description. They will not fit any original "SJD" or Yazaki shells, and while the male pin terminal is a "round pin", the female receiver terminal is actually a somewhat "triangle" shaped terminal into which a round male pin will fit.

Finally: some people wonder why one round-pin style terminal can't be stuffed into a shell from a different manufacturer. Basically, it's because the manufacturers of the shells (and their matching terminals) made their products just different enough so you had to use their complete suite of components (shells and terminals) to eliminate competitive substitution attempts. Typically, the differences involve how the metal terminal is designed and/or shaped, and specifically how the terminal is able to "latch" or "lock" into the plastic connector shell....and the unique style of "latching" also means that the internal cavity of the connector shell is unique, too (in order to accept the specialized terminal design).



HCP28301TP OEM tin-plated brass FEMALE TRUE-ROUND PIN WIRE-END TERMINAL, used with the original Yamaha female "SJD" type connector shells. Mates into the HCP28300TP male terminal. Used primarily at the handlebar control switches and the gauge clusters (XJ700 models) and a few other locations. Tin-plated solid brass terminal features retention shoulder for insertion and positive locking into their connector shell. Accepts 14-18 gauge wires. NOTE: these HCP28301TP "round-pin" terminals is used in all original connector shells that used round-pin male terminals. These terminals will not fit into the aftermarket connector shells (listed above) that are designed to accept these round-pin male terminals…..those shells above must use the HCP24540TP terminals listed further below. These HCP28301TP terminals will only fit the original shells on your harness. Each:
$ 2.95

HCP28300TP OEM tin-plated brass MALE TRUE-ROUND PIN WIRE-END TERMINAL, used with the original Yamaha female "SJD" type connector shells. Mates into the HCP28301TP female terminal. Used primarily at the handlebar control switches and the gauge clusters (XJ700 models) and a few other locations. Tin-plated solid brass terminal features retention shoulder for insertion and positive locking into their connector shell. Accepts 14-18 gauge wires. NOTE: these HCP28300TP "round-pin" terminals is used in all original connector shells that used round-pin male terminals. These terminals will not fit into the aftermarket connector shells (listed above) that are designed to accept the aftermarket round-pin male terminals…..those shells above must use the HCP24541TP terminals listed further below. These HCP28300TP terminals will only fit the original shells on your harness. Each:
$ 2.95




HCP24540TP Aftermarket tin-plated brass MALE TRUE-ROUND PIN WIRE-END TERMINAL, used with the female HCP24542F, HCP24543F, HCP24544F, and HCP24545F connector shells only. Mates into the HCP24541TP female terminal. Tin-plated solid brass terminal features retention shoulder for insertion and positive locking into their connector shell. Accepts 14-18 gauge wires. NOTE: original connector shells use the HCP28301TP round-pin terminal, aa these HCP24540TP round-pin terminals will not fit into the original connector shells that used the round-pin male terminals. These terminals will only fit into the aftermarket connector shells (listed above) that are designed to accept these aftermarket round-pin male terminals. Each:
$ 2.75

HCP24541TP Aftermarket tin-plated brass FEMALE TRUE-ROUND PIN WIRE-END TERMINAL, used with the male HCP24542M, HCP24543M, HCP24544M, and HCP24545M connector shells only. Mates to the HCP24540TP male terminal. Used primarily in the main key switch, the handlebar control switches, brake light switches on some models, fuel sender unit circuits, and a few others. Correct style tin-plated solid brass terminal features retention shoulder for insertion and positive locking into their connector shell. Accepts 14-18 gauge wires. NOTE: original connector shells use the HCP28300TP round-pin terminal, and these HCP24540TP round-pin terminals will not fit into the original connector shells that used the round-pin male terminals. These terminals will only fit into the aftermarket connector shells (listed above) that are designed to accept these aftermarket round-pin male terminals. Each:
$ 2.75



HCP9326TP Aftermarket style tin-plated brass MALE ROUND PIN STYLE WIRE-END TERMINAL, used with the female HCP9330FMxx, HCP12881FMxx, HCP12882FMxxx, HCP12885FMxx, HCP12886FMxx, and HCP13164FMxx connector shells. Mates to the HCP9327TP female terminals. Used primarily in the main key switch, the handlebar control switches, brake light switches on some models, fuel sender unit circuits, and a few others. Correct style tin-plated solid brass terminal features retention dimples for insertion and positive locking into their connector shell. Accepts 14-18 gauge wires. NOTE: original harnesses used a true "round" opening terminal. These HCP9326TP "round pin style" terminals will accept the HCP9327TP female round-pin terminals (below), but will not fit original connector shells that used the truly round-pin female terminals. Each:
$ 1.25

HCP9327TP Aftermarket style tin-plated brass FEMALE ROUND PIN STYLE PIN WIRE-END TERMINAL, used with the male HCP12881MFxx connector shell. Mates to the HCP9326TP male terminals. Used primarily in the main key switch, the handlebar control switches, brake light switches on some models, fuel sender unit circuits, and a few others. Correct style tin-plated solid brass terminal features retention dimples for insertion and positive locking into their connector shell. Accepts 14-18 gauge wires. NOTE: most original harnesses used a true "round" opening terminal. These HCP9327TP "round pin style" terminals will accept the HCP9326TP male terminals (above), but will not fit original connector shells that used the true round-pin female terminals. They will only fit into the HCP12881MFxx connector shell which is designed to use this "triangulated" round-style female terminals. Each:
$ 1.25




Original type “Fork” (or “split-ring”) type Wire-End Terminals :

These original style Bullet style Wire-End Terminals are some of the most commonly used style of connectors on your wiring harness, found on the end of brake and tail-light wire leads, turn signal leads, most of the small sending units (brake, oil, and battery fluid level sensors), brake light switches, sidestand switches, and others. All of these "open-barrel" style terminals are designed to be both crimped onto the wire insulation and to the bare wire.

HCP28305 Aftermarket original style solid brass ”FORK” STYLE WIRE-END TERMINAL is used at the neutral position switch (in the bottom of the crankcase). These “split ring” type terminal fits over the neutral switch threaded stud on all XJ650, XJ700, XJ750, and XJ900 models. Correct size and style 5mm solid brass terminal features. Accepts 14-18 gauge wires. Each:
$ 1.95



Original type Bullet Wire-End Terminals and Protective Sheathes:

These original style Bullet style Wire-End Terminals are some of the most commonly used style of connectors on your wiring harness, found on the end of brake and tail-light wire leads, turn signal leads, most of the small sending units (brake, oil, and battery fluid level sensors), brake light switches, sidestand switches, and others. All of these "open-barrel" style terminals are designed to be both crimped onto the wire insulation and to the bare wire.

NOTE: it is easy to confuse these bullet style wire-end terminals with the similar "round pin" terminals listed above. The Female Bullet Wire-End Terminals are always used inside a soft, flexible, clear plastic sheath, while the "round pin" style terminals are always inserted into a hard-shell connector body. Male Bullet Wire-End Terminals are typically "bare", although they will, on occasion, have a small, clear protective sheath around them. In any case, just remember that bullet terminals are never found within a hard plastic connector shell.

Note carefully that while the male bullet terminals are always a solitary terminal on the end of a single wire, the somewhat "promiscuous" female bullet terminals are designed to accept either one, two, or three individual male terminals. The dual- and triple-female bullet terminals are typically used to accumulate multiple smaller ground wires back into a single larger main ground wire.

The clear protective SHEATH for these bullet terminals are located further below in the "Connector Block and Terminal Sheath" section of the catalog.


HCP9364BR1418 Aftermarket original style solid brass MALE BULLET WIRE-END TERMINAL is used in a variety of different places on original harnesses. These male bullet terminals are sometimes protected by the transparent HCP9323 plastic sheath to prevent shorts and corrosion. Mates to the HCP9366xx, HCP9368xx, or HCP9328xx female bullet terminals. Correct size and style 4mm solid brass terminal features retention bulge for insertion and positive locking into their female mate. Accepts 14-18 gauge wires. Each:
$ 1.25

HCP9364TP1418 Aftermarket original style tin-plated brass MALE BULLET WIRE-END TERMINAL is used in a variety of different places on original harnesses. The tin plating gives an additional level of corrosion resistance to the brass terminal. These male bullet terminals are sometimes protected by the transparent HCP9323 plastic sheath to prevent shorts and corrosion. Mates to the HCP9366xx, HCP9368xx, or HCP9328xx female bullet terminals. Correct size and style 4mm solid brass terminal features retention bulge for insertion and positive locking into their female mate. Accepts 14-18 gauge wires. Each:
$ 1.25



HCP9366BR1418 Aftermarket original style solid brass SINGLE FEMALE BULLET WIRE-END TERMINAL is used in a variety of different places on original harnesses, especially in the lighting and sender unit circuits. These single-opening female bullet terminals are always protected by the transparent HCP9322 plastic sheath to prevent shorts and corrosion. Mates with the HCP9364xx male bullet terminals. Correct style 4mm solid brass terminal. Accepts 14-18 gauge wires. Each:
$ 1.25

HCP9366TP1418 Aftermarket original style tin-plated brass SINGLE FEMALE BULLET WIRE-END TERMINAL is used in a variety of different places on original harnesses, especially in the lighting and sender unit circuits. The tin plating gives an additional level of corrosion resistance to the brass terminal. These single-opening female bullet terminals are always protected by the transparent HCP9322 plastic sheath to prevent shorts and corrosion. Mates with the HCP9364xx male bullet terminals. Correct style 4mm tin-plated solid brass terminal. Accepts 14-18 gauge wires. Each:
$ 1.25



HCP9368BR1418 Aftermarket original style solid brass DOUBLE FEMALE BULLET WIRE-END TERMINAL is used in a variety of different places on original harnesses, especially in the turn signal circuits. These dual-receiver female bullet terminals are always protected by the transparent HCP9324 plastic sheath to prevent shorts and corrosion. Mates with the HCP9364xx male bullet terminals. Correct style 4mm solid brass terminal. Accepts 14-18 gauge wires. Each:
$ 1.25

HCP9368TP1418 Aftermarket original style tin-plated brass DOUBLE FEMALE BULLET WIRE-END TERMINAL is used in a variety of different places on original harnesses, especially in the turn signal circuits. The tin plating gives an additional level of corrosion resistance to the brass terminal. These dual-receiver female bullet terminals are always protected by the transparent HCP9324 plastic sheath to prevent shorts and corrosion. Mates with the HCP9364xx male bullet terminals. Correct style 4mm tin-plated solid brass terminal. Accepts 14-18 gauge wires. Each:
$ 1.25



HCP9328BR1418 Aftermarket original style solid brass TRIPLE FEMALE BULLET WIRE-END TERMINAL is used on the rear tailight harness on XJ550 Maxim and 1982-83 XJ650 Maxim models only. These triple-hole female bullet terminals are always protected by the transparent HCP9329 plastic sheath to prevent shorts and corrosion. Mates with the HCP9364xx male bullet terminals. Correct style 4mm solid brass terminal. Accepts 14-18 gauge wires. Each:
$ 1.25



Bullet Terminal Clear Protective Sheaths:

HCP9323 Aftermarket original style MALE BULLET STYLE WIRE-END TERMINAL PROTECTIVE SHEATH, correct size and length transparent sheath fits the HCP9364 male wire-end terminal. Each:
$ 1.25

HCP9322 Aftermarket original style SINGLE FEMALE BULLET STYLE WIRE-END TERMINAL PROTECTIVE SHEATH, correct size and length transparent sheath fits the HCP9366 female wire-end terminal. Each:
$ 1.95

HCP9324 Aftermarket original style DUAL FEMALE BULLET STYLE WIRE-END TERMINAL PROTECTIVE SHEATH, correct size and length transparent sheath fits the HCP9368 female wire-end terminal. Each:
$ 1.25

HCP9329 Aftermarket original style TRIPLE FEMALE BULLET STYLE WIRE-END TERMINAL PROTECTIVE SHEATH, correct size and length transparent sheath fits the HCP9328 female wire-end terminal. Each:
$ 1.25



Original type Closed Round Ring Terminals:

These original style Round Closed Ring "Eye" Wire-End Terminals are primarily used on your wiring harness for frame grounding purposes. In many cases, a number of different harness ground wires (which are always black) come together and are terminated within a single closed ring "eye" style terminal. All of these "open-barrel" style terminals are designed to be both crimped onto the wire insulation and to the bare wire.


HCP10093BR1214 Aftermarket original style brass CLOSED RING WIRE-END TERMINAL, for 12-14 gauge wires as used on most models, typically at the coil mounting bolt or at some other main harness-to-frame ground location. These wire-end terminals are NOT used on battery cables! Each:
$ 1.25

HCP10093BR1618 Aftermarket original style brass CLOSED RING WIRE-END TERMINAL, for 14-18 gauge wires as used on some ground positions on XJ750 Maxim and XJ1100 models. All other bikes use the larger 12-14 gauge version of this terminal (above). These wire-end terminals are NOT used on battery cables! Each:
$ 1.25

HCP14736 Aftermarket original style brass CLOSED RING WIRE-END TERMINAL, for 18-22 gauge wires as used on some wires inside the handlebar control switches. These very small terminals are used in different quantities depending on model and year of the bike. Each:
$ 1.95



Aftermarket Butt Connector Terminals:

When you want to permanently join two pieces of wire that will not ever need to be disconnected at that joint, then a tubular BUTT CONNECTOR is the proper terminal style to use. Available in either un-insulated or fully insulated versions, there's a size and style for any situation you might encounter, including STEP-DOWN BUTT CONNECTORS when joining two wires of greatly differing sizes (for instance, joining a 12-gauge size wire to an 18-gauge size wire), as well as the latest technological miracle, the CRIMPABLE, HEAT-SHRINK, SOLDER-SLEEVE BUTT CONNECTOR.

Please keep these definitions in mind when determining which type of connector is best suited for your needs:

Crimpable means that you insert the bare wire end into the hollow central cavity of this tube-like butt connector terminal, and then crush the tube with a proper style "closed barrel" terminal crimper tool. This process mechanically captures the bare wire only (and not the insulation) securely inside the connector.

Non-insulated means that the butt connector is a bare terminal; it has no protective sleeve over it, and thus should be covered with shrink tube or electrical tape of some type after the wire are installed and the connector crimped and soldered to the wires.

An insulated connector, or the other hand, comes with a hard plastic outer insulation or, even better, with a heat-shrink material as part of the terminal, making the entire installation process that much simpler.

Solder-sleeve means that the terminal has an internal slug of solder so that while you're heating the shrink sleeve, you'll also melt an internal solder ring that then flows and fills the internal cavity of the connector (and thus the bare wire) with a warm, solder-y goodness.

Now, is this a great country, or what?


Please note that each Butt Connector terminal only fits a certain range of wire sizes, so make sure you order the proper size for the wire(s) that you'll be joining. It's pretty useful to keep a variety of sizes available for use.

All of these terminals are a "closed-barrel" style, and require a proper style crimping tool for such type connectors, which can be found further below in the "Electrical Tools" section.



HCP13042 Aftermarket wire-joining CRIMPABLE, NON-INSULATED BUTT CONNECTOR, for wires that are both 18-22 gauge. NOTE: the HCP13030, HCP13036, HCP13033, or HCP13038 insulating shrink-tube is the proper size to use with these butt connectors. Each:
$ 0.95

HCP13042SET10 Aftermarket wire-joining CRIMPABLE, NON-INSULATED BUTT CONNECTORS, for wires that are both 18-22 gauge. Set of 10:
$ 7.95


HCP13045 Aftermarket wire-joining CRIMPABLE, HEAT-SHRINK INSULATED, SOLDER-SLEEVE BUTT CONNECTOR, for wires that are both 18-22 gauge. Each:
$ 1.95

HCP13045SET10 Aftermarket wire-joining CRIMPABLE, HEAT-SHRINK INSULATED, SOLDER-SLEEVE BUTT CONNECTORS, for wires that are both 18-22 gauge. Set of 10:
$ 16.95




HCP13043 Aftermarket wire-joining CRIMPABLE, NON-INSULATED BUTT CONNECTOR, for wires that are both 14-16 gauge. NOTE: the HCP13031, HCP13037, HCP13034, or HCP13039 insulating shrink-tube is the proper size to use with these butt connectors. Each:
$ 1.95

HCP13043SET10 Aftermarket wire-joining CRIMPABLE, NON-INSULATED BUTT CONNECTORS, for wires that are both 14-16 gauge. Set of 10:
$ 7.95


HCP13046 Aftermarket wire-joining CRIMPABLE, HEAT-SHRINK INSULATED, SOLDER-SLEEVE BUTT CONNECTOR, for wires that are both 14-16 gauge. Each:
$ 1.95

HCP13046SET10 Aftermarket wire-joining CRIMPABLE, HEAT-SHRINK INSULATED, SOLDER-SLEEVE BUTT CONNECTORS, for wires that are both 14-16 gauge. Set of 10:
$ 16.95




HCP13044 Aftermarket wire-joining CRIMPABLE, NON-INSULATED BUTT CONNECTOR, for wires that are both 10-12 gauge. NOTE: the HCP13032 or HCP13035 insulating shrink-tube is the proper size to use with these butt connectors. Each:
$ 1.95

HCP13044SET10 Aftermarket wire-joining CRIMPABLE, NON-INSULATED BUTT CONNECTORS, for wires that are both 10-12 gauge. Set of 10:
$ 7.95


HCP13047 Aftermarket wire-joining CRIMPABLE, HEAT-SHRINK INSULATED, BUTT CONNECTOR, for wires that are both 10-12 gauge. Each:
$ 1.95

HCP13047SET10 Aftermarket wire-joining CRIMPABLE, HEAT-SHRINK INSULATED, BUTT CONNECTORS, for wires that are both 10-12 gauge. Set of 10:
$ 16.95




HCP13069 Aftermarket wire-joining CRIMPABLE, NON-INSULATED STEP-DOWN BUTT CONNECTOR, used for joining two significantly different size wires together. One "end" of the terminal accept wires that are 10-12 gauge, while the other end accepts 14-16 gauge wire. NOTE: the HCP13032 or HCP13035 insulating shrink-tube is the proper size to use with these butt connectors. Each:
$ 1.95

HCP13069SET10 Aftermarket wire-joining CRIMPABLE, NON-INSULATED STEP-DOWN BUTT CONNECTORS, One "end" of the terminal accept wires that are 10-12 gauge, while the other end accepts 14-16 gauge wire. Set of 10:
$ 16.95


HCP13070 Aftermarket wire-joining CRIMPABLE, INSULATED STEP-DOWN BUTT CONNECTOR, used for joining two significantly different size wires together. One "end" of the terminal accept wires that are 10-12 gauge, while the other end accepts 14-16 gauge wire. Each:
$ 1.95

HCP13070SET10 Aftermarket wire-joining CRIMPABLE, INSULATED STEP-DOWN BUTT CONNECTORS, One "end" of the terminal accept wires that are 10-12 gauge, while the other end accepts 14-16 gauge wire. Set of 10:
$ 16.95




HCP13071 Aftermarket wire-joining CRIMPABLE, NON-INSULATED STEP-DOWN BUTT CONNECTOR, used for joining two significantly different size wires together. One "end" of the terminal accept wires that are 14-16 gauge, while the other end accepts 18-22 gauge wire. NOTE: the HCP13031, HCP13037, HCP13034, or HCP13039 insulating shrink-tube is the proper size to use with these butt connectors. Each:
$ 1.95

HCP13071SET10 Aftermarket wire-joining CRIMPABLE, NON-INSULATED BUTT CONNECTORS, One "end" of the terminal accept wires that are 14-16 gauge, while the other end accepts 18-22 gauge wire. Set of 10:
$ 16.95


HCP13072 Aftermarket wire-joining CRIMPABLE, INSULATED STEP-DOWN BUTT CONNECTOR, used for joining two significantly different size wires together. One "end" of the terminal accept wires that are 14-16 gauge, while the other end accepts 18-22 gauge wire. Each:
$ 1.95

HCP13072SET10 Aftermarket wire-joining CRIMPABLE, INSULATED BUTT CONNECTORS, One "end" of the terminal accept wires that are 14-16 gauge, while the other end accepts 18-22 gauge wire. Set of 10:
$ 16.95



Aftermarket Insulation-Piercing Wire Tapping Connectors:

These easy-to-use, "fold-over tab" wire splicing taps allow you to "tap into" an existing wire without cutting, splicing, or soldering. Guillotine blade will tap into an existing wire, and makes the connection to a new wire a snap. No crimping tool required; a standard set of pliers will work just fine.

HCP14292 Aftermarket insulation-piercing WIRE TAP CONNECTOR, accepts 14-18 gauge wires. Standard style does not have moisture protection. Each:
$ 2.95

HCP14913 Aftermarket insulation-piercing WIRE TAP CONNECTOR, accepts 14-18 gauge wires. Moisture-proof style is filled with an insulating, protective gel that seals the wires. Each:
$ 3.95



Aftermarket Flat Blade Wire-End Terminals:

When you want to join two pieces of wire that may or will need to be disconnected at that joint, then a matching set of male and female FLAT BLADE CONNECTORS are the terminal type to use. Although there are a number of different styles of these terminals available in the marketplace, we offer what we feel are the easiest and most secure style available, the infamous CRIMPABLE, HEAT-SHRINK, SOLDER-SLEEVE FLAT BLADE TERMINAL design which combines all of the necessary features of a proper terminal installation---it gets crimped tightly to the wire, the wire and the terminal are already covered with a heat-shrink tube for insulation, and the wire gets soldered to the terminal----all in one graceful and easy-to-use little package.

Please note that Flat Blade Terminals properly fit only a certain range of wire sizes, so make sure you order the proper size for the wire(s) that you'll be joining. It's pretty useful to keep a variety of sizes available for use.

All of these "closed-barrel" style terminals are designed to be crimped onto the bare wire core only.


HCP13049 Aftermarket wire-end CRIMPABLE, HEAT-SHRINK INSULATED, SOLDER-SLEEVE MALE FLAT BLADE TERMINAL, for wires that are 18-22 gauge. Each:
$ 3.95

HCP13049SET10 Aftermarket wire-joining CRIMPABLE, HEAT-SHRINK INSULATED, SOLDER-SLEEVE MALE FLAT BLADE TERMINALS, for wires that are 18-22 gauge. Set of 10:
$ 29.95


HCP13048 Aftermarket wire-end CRIMPABLE, HEAT-SHRINK INSULATED, SOLDER-SLEEVE FEMALE FLAT BLADE TERMINAL, for wires that are 18-22 gauge. Each:
$ 3.95

HCP13048SET10 Aftermarket wire-joining CRIMPABLE, HEAT-SHRINK INSULATED, SOLDER-SLEEVE FEMALE FLAT BLADE TERMINALS, for wires that are 18-22 gauge. Set of 10:
$ 29.95




HCP13051 Aftermarket wire-end CRIMPABLE, HEAT-SHRINK INSULATED, SOLDER-SLEEVE MALE FLAT BLADE TERMINAL, for wires that are 14-16 gauge. Each:
$ 3.95

HCP13051SET10 Aftermarket wire-joining CRIMPABLE, HEAT-SHRINK INSULATED, SOLDER-SLEEVE MALE FLAT BLADE TERMINALS, for wires that are 14-16 gauge. Set of 10:
$ 29.95


HCP13050 Aftermarket wire-end CRIMPABLE, HEAT-SHRINK INSULATED, SOLDER-SLEEVE FEMALE FLAT BLADE TERMINAL, for wires that are 14-16 gauge. Each:
$ 3.95

HCP13050SET10 Aftermarket wire-joining CRIMPABLE, HEAT-SHRINK INSULATED, SOLDER-SLEEVE FEMALE FLAT BLADE TERMINALS, for wires that are 14-16 gauge. Set of 10:
$ 27.95




HCP13053 Aftermarket wire-end CRIMPABLE, HEAT-SHRINK INSULATED, SOLDER-SLEEVE MALE FLAT BLADE TERMINAL, for wires that are 10-12 gauge. Each:
$ 3.95

HCP13053SET10 Aftermarket wire-joining CRIMPABLE, HEAT-SHRINK INSULATED, SOLDER-SLEEVE MALE FLAT BLADE TERMINALS, for wires that are 10-12 gauge. Set of 10:
$ 27.95


HCP13052 Aftermarket wire-end CRIMPABLE, HEAT-SHRINK INSULATED, SOLDER-SLEEVE FEMALE FLAT BLADE TERMINAL, for wires that are 10-12 gauge. Each:
$ 3.95

HCP13052SET10 Aftermarket wire-joining CRIMPABLE, HEAT-SHRINK INSULATED, SOLDER-SLEEVE FEMALE FLAT BLADE TERMINALS, for wires that are 10-12 gauge. Set of 10:
$ 27.95




Aftermarket 90-Degree Flat Blade "Flag" Wire-End Terminals:

These "flag" style terminals allow a 90-degree bend to the wire direction, and are normally used on the horn lead wires, inside the flasher relay connector shell, and inside some styles of the headlight plug connector shell. They accept a bare wire input and allow attachment to a male “medium width” (.250”) flat blade terminal (this terminal has a female receiver).

All of these "closed-barrel" style terminals are designed to be crimped onto the bare wire core only.

HCP24210 Aftermarket "medium-width" 90-degree FEMALE MEDIUM-WIDTH FLAT BLADE WIRE-END “FLAG” TERMINAL, tin-plated solid brass terminal features a blue nylon insulation shell. Accepts 14-16 gauge wires. Each:
$ 2.95

HCP24210SET5 Aftermarket "medium-width" 90-degree FEMALE MEDIUM-WIDTH FLAT BLADE WIRE-END “FLAG” TERMINAL, tin-plated solid brass terminal features a blue nylon insulation shell. Accepts 14-16 gauge wires. Set of 5:
$ 12.95


HCP24211 Aftermarket "medium-width" 90-degree FEMALE MEDIUM-WIDTH FLAT BLADE WIRE-END “FLAG” TERMINAL, tin-plated solid brass terminal features a red nylon insulation shell. Accepts 18-22 gauge wires. Each:
$ 2.95

HCP24211SET5 Aftermarket "medium-width" 90-degree FEMALE MEDIUM-WIDTH FLAT BLADE WIRE-END “FLAG” TERMINAL, tin-plated solid brass terminal features a red nylon insulation shell. Accepts 18-22 gauge wires. Set of 5:
$ 12.95




WIRE-END TERMINAL CONNECTOR BLOCKS:

When a number of circuits (and thus their wires) all go to the same functional area......for instance, to the speedometer cluster.........then all of the particular wire end terminals are placed in specific locations within a plastic CONNECTOR SHELL or "BLOCK" that holds all of the end terminals in a particular orientation, and encased in a protective hard plastic, colored shell. These connector shells or "blocks" come in a variety of configurations, based on how many wire terminals they hold (1, 2, 3, all the way up to 9 positions), their physical configurations (straight across, T-shaped, rectangular, etc.), their color (most are white or off-white, but some are black, red, green, or even blue), and whether the connector shells have mechanical latches on them (most do not, but some of the most vital, "must not come part" connector blocks----such as the main power lead from the battery, and the coil primary input leads----have fail-safe latches to increase their security).

The original style CONNECTOR BLOCKS listed below are sorted by how many wire end terminals they are capable of holding, and each is listed as to where it used on the each model bike harness, and on which side of the connection it is used on. They will correctly replace and mate with the stock connector shells already on your harness, eliminating the need (and temptation!) to fill up your harness with blue butt splices and bathroom caulking whenever a harness repair is needed........

NOTE: all connectors shells and blocks listed below are for use with original style OEM "open barrel" wire end terminals listed above only! (unless otherwise specified)


Single-terminal Connector Blocks:

HCP12837FMOWT Aftermarket off-white plastic FEMALE CONNECTOR SHELL, single place, used on all of the following circuits listed below. Accepts the HCP9371BR1418 male flat-blade terminal. Each:
$ 5.95

* HCP12837FMOWT (the female shell with the male latching peg) is used on:
- Main battery power lead-in harness, on the main harness side of the connection: all XJ models except XJ1100 models.



HCP12837MFWHT Aftermarket white plastic MALE CONNECTOR SHELL, single place, used on all of the following circuits listed below. Accepts the HCP12898BR1418 female flat-blade terminal. Each:
$ 5.95

* HCP12837MFWHT (the male shell with the female latching peg) is used on:
- Main battery power lead-in harness, on the positive battery cable harness side of the connection: all XJ models except XJ1100 models.





HCP13489MNWHT Aftermarket white plastic MALE CONNECTOR SHELL, single place, used on all of the following circuits listed below. Accepts the HCP9360xx male flat-blade terminal. Each:
$ 5.95

* HCP13489MNWHT (the male shell with the male latching peg) is used on:
- Main battery power lead-in harness, on the main harness side of the connection: all XJ1100 models. NOTE: differ very slightly in configuration from original but will fit and function correctly.



HCP13489FNWHT Aftermarket white plastic MALE CONNECTOR SHELL, single place, used on all of the following circuits listed below. Accepts the HCP9361xx female flat-blade terminal. Each:
$ 5.95

* HCP13489FNWHT (the female shell with the female latching peg) is used on:
- Main battery power lead-in harness, on the positive battery cable harness side of the connection: all XJ1100 models. NOTE: differ very slightly in configuration from original but will fit and function correctly.




Two-terminal Connector Blocks:

HCP24542FMWHT Aftermarket white plastic FEMALE CONNECTOR SHELL, 2-place “flat” terminal orientation, used on all of the following circuits listed below. Accepts the HCP24540TP round-pin male terminal only (does not accept original terminals) Each:
$ 8.95

* HCP24542FMWHT (the female shell) is used on:
- Emergency Stop Switch harness, on the main harness side of the connection: XJ650 Turbo and XJ1100 models.
- Auxiliary Light Switch (under the right handlebar switch harness), on the main harness side of the connection: 1982 XJ750 Maxim models.
- Front Brake Switch, on the main harness side of the connection: all 1985-1986 XJ700 models and XJ750-X models.
- Main Switch, for battery fluid sensor, on the switch lead-in harness: XJ650 Turbo, 1982 XJ750 Maxim, 1981-83 XJ750 Seca models, and XJ1100 models.
- Fuel level sensor (fuel tank sending unit), on the sender unit lead-in harness: 1985-1986 all XJ700 and XJ750-X models, and all XJ900 models.



HCP24542MFWHT Aftermarket white plastic MALE CONNECTOR SHELL, 2-place “flat” terminal orientation, used on all of the following circuits listed below. Accepts the HCP24541TP round-pin female terminal only (does not accept original terminals). Each:
$ 8.95

* HCP24542MFWHT (the male shell) is used on:
- Emergency Stop Switch harness, on the switch lead-in harness: XJ650 Turbo and XJ1100 models.
- Auxiliary Light Switch (under the right handlebar switch harness), on the switch lead-in harness: 1982 XJ750 Maxim models.
- Front Brake Switch, on the switch lead-in harness: all 1985-1986 XJ700 models and XJ750-X models.
- Main Switch, for battery fluid sensor, on the main harness side of the connection: XJ650 Turbo, 1982 XJ750 Maxim, 1981-83 XJ750 Seca models, and XJ1100 models.
- Fuel level sensor (fuel tank sending unit), on the main harness side of the connection: 1985-1986 all XJ700 and XJ750-X models, and all XJ900 models.




HCP13161FNWHT Aftermarket white plastic FEMALE CONNECTOR SHELL, 2-place, "T"-shaped (horizontal above vertical terminal orientation), used on all of the following circuits listed below. Accepts the HCP9360xx male terminal. Each:
$ 5.95

* HCP13161FNWHT (the female shell) is used on:
- Horn lead harness, on the main harness side of the connection: all XJ900 models.



HCP13161MNWHT Aftermarket white plastic MALE CONNECTOR SHELL, 2-place, "T"-shaped (horizontal above vertical terminal orientation), used on all of the following circuits listed below. Accepts the HCP9361xx female terminal. Each:
$ 5.95

* HCP13161MNWHT (the male shell) is used on:
- Horn lead harness, on the horn harness side of the connection: all XJ900 models.





HCP9331FMWHT Aftermarket white plastic FEMALE CONNECTOR SHELL, 2-place (horizontal above horizontal terminal orientation) with a male latching peg, used on all of the following circuits listed below.
Accepts the HCP9360xx male flat-blade terminal. Each:
$ 9.95

* HCP9331FMWHT (the female shell with the male latching peg) is used on:
- Alternator rotor lead harness, on the brush plate lead-in harness side of the connection: all XJ-series bikes (except XJ1100).
- Alternator rotor lead harness, on the main harness side of the connection: all XJ1100 models.
- Fan motor, on the fan motor lead-in harness side of the connection: all XJ700-X and XJ750-X models. NOTE: all XJ700-X and XJ750-X models used a black-colored version of this same connector shell which is not currently available.
- Fuel pump circuit, on the fuel pump lead-in harness side of the connection: all XJ650 Turbo models.
- Ignition Coils lead harness, on the main harness side of the connection: all XJ-series bikes. NOTE: all XJ700 models and the XJ750-X models used a yellow-colored version of this same connector shell which is not currently available.
- Knock sensor circuit, on the main harness side of the connection: all XJ650 Turbo models.
- Main system circuit (30A) fuseholder, on the fuseholder lead-in harness side of the connection: all XJ700, XJ750-X, and XJ1100 models.
- Sidestand switch lead, on the main harness side of the connection: all XJ550, 1982-83 XJ650 Maxim, all XJ700, XJ750-X, and XJ900 models.
- Starter solenoid lead harness, on the main harness side of the connection: all XJ-series bikes (except all XJ700 and XJ750-X models).



HCP9331MFWHTWE Aftermarket white plastic MALE CONNECTOR SHELL, 2-place (horizontal above horizontal terminal orientation) with a female latch-peg receiver and side ear "tabs", used on all of the following circuits listed below. Accepts the HCP9361xx female flat-blade terminal. Each:
$ 5.95

* HCP9331MFWHTWE (the male shell with the female latch-peg receiver and the side "ear" tabs) is used on:
- Alternator rotor lead harness, on the main harness side of the connection: all XJ-series bikes (except XJ1100).
- Alternator rotor lead harness, on the brush plate lead-in harness side of the connection: all XJ1100 models.
- Fan motor, on the main harness side of the connection: all XJ700-X and XJ750-X models. NOTE: all XJ700-X and XJ750-X models used a black-colored version of this same connector shell which is not currently available.
- Fuel pump circuit, on the main harness side of the connection: all XJ650 Turbo models.
- Ignition Coils lead harness, on the ignition coils lead-in harness side of the connection: all XJ-series bikes. NOTE: all XJ700 models and the XJ750-X models used a yellow-colored version of this same connector shell which is not currently available.
- Knock sensor circuit, on the sensor lead-in harness side of the connection: all XJ650 Turbo models.
- Main system circuit (30A) fuseholder, on the main harness side of the connection: all XJ700, XJ750-X, and XJ1100 models.
- Sidestand switch lead, on the sidestand switch lead-in harness side of the connection: all XJ550, 1982-83 XJ650 Maxim, all XJ700, XJ750-X, and XJ900 models.
- Starter solenoid lead harness, on the solenoid lead-in harness side of the connection: all XJ-series bikes (except all XJ700 and XJ750-X models).




Three-terminal Connector Blocks:

HCP24543FMWHT Aftermarket white plastic FEMALE CONNECTOR SHELL, 3-place “T-shaped” terminal orientation, used on all of the following circuits listed below. Accepts the HCP24540TP round-pin male terminal only (does not accept original terminals). Each:
$ 8.95

* HCP24543FMWHT (the female shell) is used on:
- Left Handlebar Control Switch, on the main harness side of the connection: all XJ550 models, all XJ650, all XJ750 Maxim models, and aXJ1100 models.



HCP24543MFWHT Aftermarket white plastic MALE CONNECTOR SHELL, 3-place “T-shaped” terminal orientation, used on all of the following circuits listed below. Accepts the HCP24541TP round-pin female terminal only (does not accept original terminals). Each:
$ 8.95

* HCP24543MFWHT (the male shell) is used on:
- Left Handlebar Control Switch, on the switch lead-in harness: all XJ550 models, all XJ650, all XJ750 Maxim models, and aXJ1100 models.




HCP12838MNBLK Aftermarket black plastic MALE CONNECTOR SHELL, 3-place, "T"-shaped, used on all of the following circuits listed below. This shell has a hinged rear "flap" that covers the terminals after they are installed into the shell. Accepts the HCP9370BR1418 female 90-degree flat-blade terminal. Each:
$ 7.95

* HCP12838MNBLK (the male shell) is used on:
- Flasher Relay, on the main harness side of the connection: all XJ models except all XJ700 models, XJ750-X models, 1983 XJ750 Maxim and Midnight Maxim models, and XJ900 models.
- Headlight, on the main harness side of the connection: all XJ models except 1983 XJ750 Maxim and Midnight Maxim models (although they can use this shell instead of the correct HCP13572MNBLK shell).



HCP13572MNBLK Aftermarket black plastic MALE CONNECTOR SHELL, 3-place, "T"-shaped, used on all of the following circuits listed below. This shell does not have a hinged rear "flap". Accepts the HCP12898BR1418 female flat-blade terminal. Each:
$ 7.95

* HCP13572MNBLK (the male shell) is used on:
- Flasher Relay, on the main harness side of the connection: all 1983 XJ750 Maxim and Midnight Maxim models, and XJ900 models.
- Headlight, on the main harness side of the connection: all 1983 XJ750 Maxim and Midnight Maxim models.



HCP13571 Aftermarket black plastic MALE CONNECTOR SHELL, 3-place, "T"-shaped, used on all of the following circuits listed below. This shell has a hinged rear "flap" that covers the terminals after they are installed into the shell. Includes the HCP9370BR1418 terminals already installed and a 12" wire lead of 16 AWG wire from each terminal. NOTE: on models using the "computer" dash, you will need to retain your original short jumper wire(s) from various lead(s) that are used to control the high-beam warning indicator light on the dash and splice them into the new leads. Each:
$ 8.95

* HCP13571 (the male shell) is used on:
- Headlight, on the main harness side of the connection: all XJ models except 1983 XJ750 Maxim and Midnight Maxim models (although they can use this shell instead of the correct HCP13572MNBLK shell).



HCP13575 Aftermarket high-performance ceramic MALE CONNECTOR SHELL, 3-place, "T"-shaped, used on all of the following circuits listed below. This shell is made from a high-temp ceramic material for use when running high-wattage replacement headlight bulbs. Includes the HCP9370BR1418 terminals already installed and a 12" wire lead of 16 AWG wire from each terminal. NOTE: on models using the "computer" dash, you will need to retain your original short jumper wire(s) from various lead(s) that are used to control the high-beam warning indicator light on the dash and splice them into the new leads. Each:
$ 19.95

* HCP13575 (the male shell) is used on:
- Headlight, on the main harness side of the connection: all XJ models except 1983 XJ750 Maxim and Midnight Maxim models (although they can use this shell instead of the correct HCP13572MNBLK shell).





HCP9333MFWHTNE Aftermarket white plastic MALE CONNECTOR SHELL, 3-place, "T"-shaped with a with a female latch-peg receiver, used on all of the following circuits listed below. Accepts the HCP9361xx female flat-blade terminal. Each:
$ 5.95

- Alternator stator lead harness, on the stator lead-in harness side of the connection: all XJ-series bikes (except XJ1100).
- Tail Light Lead Harness, on the main harness side of the connection: all XJ550 Seca, all XJ650 Turbo, and all XJ900 models.



HCP9333FMWHT Aftermarket white plastic FEMALE CONNECTOR SHELL, 3-place, "T"-shaped with a male latching peg, used on all of the following circuits listed below. Accepts the HCP9360xx male flat-blade terminal. Each:
$ 5.95

* HCP9333FMWHT (the female shell with the male latching peg) is used on:
- Alternator stator lead harness, on the main harness side of the connection: all XJ-series bikes (except XJ1100).
- Boost Pressure Sensor, on the sensor lead-in harness side of the connection: XJ650 Turbo models.
- Boost Switch, on the sensor lead-in harness, main harness end: XJ1100 models.
- Headlight extension harness, on the main harness side of the connection: all XJ550 and XJ650 (except Turbo) models.
- Main Key Switch lead-in harness, on the main switch lead-in harness side of the connection: all XJ-series bikes (except XJ1100). NOTE: the wires in the above circuit are 14-gauge red, 14-gauge brown, and 18-gauge blue, so choose your terminals appropriately. Bikes that use the two red/white wires for the battery sensor have two additional 20-gauge wires.
- Sidestand switch lead, on the main harness side of the connection: all XJ650RJ Seca, XJ650 Turbo, all 1981-83 XJ750 models, and XJ1100 models.
- Tail Light Lead Harness, on the tail light side of the connection: all XJ550 Seca, all XJ650 Turbo, and all XJ900 models.



HCP9333MFWHTWE Aftermarket white plastic MALE CONNECTOR SHELL, 3-place, "T"-shaped with a with a female latch-peg receiver and side "ear" tabs, used on all of the following circuits listed below. Accepts the HCP9361xx female flat-blade terminal. Each:
$ 5.95


* HCP9333MFWHTWE (the male shell with the female latch-peg receiver and side "ear" tabs) is used on:
- Boost Pressure Sensor, on the main harness side of the connection: XJ650 Turbo models.
- Boost Switch, on the main harness side of the connection: XJ1100 models.
- Headlight extension harness, on the extension harness side of the connection: all XJ550 and XJ650 (except Turbo) models.
- Main Key Switch lead-in harness, on the main harness side of the connection: all XJ-series bikes (except XJ1100). NOTE: the wires in the above circuit are 14-gauge red, 14-gauge brown, and 18-gauge blue, so choose your terminals appropriately. Bikes that use the two red/white wires for the battery sensor have two additional 20-gauge wires.
- Sidestand switch lead, on the switch lead-in harness side of the connection: all XJ650RJ Seca, XJ650 Turbo, all 1981-83 XJ750 models, and XJ1100 models.





NOTE: either of the following connector shells (HCP9337-series) below can be used in place of the original green shell used for the clutch hand lever switch (the original green shell is not available, but these shells are identical in size/shape/fit/etc.):

NOTE: either of the following connector shells (HCP9337-series) below can be used in place of the original green shell used for the clutch hand lever switch (the original green shell is not available, but these shells are identical in size/shape/fit/etc.):


HCP9337FNOWT Aftermarket off-white plastic FEMALE CONNECTOR SHELL, 3-place, horizontal, used on all of the following circuits listed below. Accepts the HCP9362xx male flat-blade terminal. Each:
$ 5.95

* HCP9337FNOWT (the female shell) is used on:
- Dash Turn Signal Indicator Lights harness, on the main harness side of the connection: XJ1100 models.
- Fuel level sensor (in gas tank), on the main harness side of the connection: all XJ550 Seca, XJ650 Turbo, 1982 XJ750 Maxim, 1981-83 XJ750 Seca, and XJ1100 models.
- Tachometer harness, main harness side of the connection: all XJ550 Maxim, 1980-81 XJ650 Maxim and Midnight Maxim, XJ650RJ Seca, 1982 XJ750 Maxim, and 1981-83 XJ750 Seca models.
- Terminal assembly harness, main harness side of the connection: XJ1100 models.
- Clutch hand lever switch harness, main harness side of the connection, for all XJ550, XJ650, XJ750 (except Seca models), XJ700, XJ750-X, and XJ1100 models. Note that this shell was originally green in color, but this shell---although the wrong color----is the same size, shape, and fit.



HCP9337MNOWTNE Aftermarket off-white plastic MALE CONNECTOR SHELL, 3-place, horizontal, used on all of the following circuits listed below. Accepts the HCP9363BRD1418 or HCP9363BRD1822 female flat-blade terminal. Each:
$ 5.95

* HCP9337MNOWTNE (the male shell) is used on:
- Dash Turn light indicator harness, on the dash lights lead-in harness side of the connection: XJ1100 models.
- Fuel level sensor (in gas tank), on the fuel sender unit lead-in harness side of the connection: all XJ550 Seca, XJ650 Turbo, 1982 XJ750 Maxim, 1981-83 XJ750 Seca, and XJ1100 models.
- Tachometer harness, on the tachometer lead-in harness side of the connection: all XJ550 Maxim, 1980-81 XJ650 Maxim and Midnight Maxim, XJ650RJ Seca, 1982 XJ750 Maxim, and 1981-83 XJ750 Seca models.
- Terminal assembly harness, on the terminal assembly lead-in harness side of the connection: XJ1100 models.
- Clutch hand lever switch harness, clutch switch harness side of the connection, for all XJ550, XJ650, XJ750 (except Seca models), XJ700, XJ750-X, and XJ1100 models. Note that this shell was originally green in color, but this shell---although the wrong color----is the same size, shape, and fit.





HCP9337FNYEL Aftermarket yellow plastic FEMALE CONNECTOR SHELL, 3-place, horizontal, used on all of the following circuits listed below. Accepts the HCP9362xx male flat-blade terminal. Each:
$ 5.95

* HCP9337FNYEL (the female shell) is used on:
- Dash Neutral and Turn Signal lights indicator harness, on the main harness side of the connection: all 1982 XJ750 Maxim and 1981-83 XJ750 Seca models.
- Clutch hand lever switch harness, main harness side of the connection, for all XJ550, XJ650, XJ750 (except Seca models), XJ700, XJ750-X, and XJ1100 models. Note that this shell was originally green in color, but this shell---although the wrong color----is the same size, shape, and fit.



HCP9337MNYELNE Aftermarket yellow plastic MALE CONNECTOR SHELL, 3-place, horizontal, used on all of the following circuits listed below. Accepts the HCP9363BRD1418 or HCP9363BRD1822 female flat-blade terminal. Each:
$ 5.95

* HCP9337MNYELNE (the male shell) is used on:
- Dash Neutral and Turn Signal lights indicator harness, on the dash indicator light lead-in harness side of the connection: all 1982 XJ750 Maxim and 1981-83 XJ750 Seca models.
- Clutch hand lever switch harness, clutch switch harness side of the connection, for all XJ550, XJ650, XJ750 (except Seca models), XJ700, XJ750-X, and XJ1100 models. Note that this shell was originally green in color, but this shell---although the wrong color----is the same size, shape, and fit.




Four-terminal Connector Blocks:

NOTE: all sidestand, starting circuit, headlamp, fuel pump, and emergency stop relay could have come either with or without a terminal latch shroud which surrounds the brass terminals on the relay. Although you can use either the HCP9334MNWHTNE (no latch) connector shell or the HCP9334MMWHTNE (with male latch) connector shell, if your relay has the terminal shroud on it (most original relays did not have the shroud, but most current replacement relays do have the shroud, whether or not the original relay did), then you should use the HCP9334MMWHTNE connector shell, as it has the proper style integral male latch that latches onto the female receiver that is part of (and the reason for!) that terminal "shroud" on the relay base.


HCP24544FFWHT Aftermarket white plastic FEMALE CONNECTOR SHELL, 4-place square terminal orientation, used on all of the following circuits listed below. Accepts the HCP24540TP round-pin male terminal only (does not accept original terminals). Each:
$ 8.95

* HCP24544FFWHT (the female shell) is used on:
- Left Handlebar Control Switch, on the main harness side of the connection: 1981-1983 XJ750 Seca models.
- Fusebox (in dash), on the fusebox lead-in harness: 1985-86 XJ700 all models and XJ750-X models.



HCP24544MMWHT Aftermarket white plastic MALE CONNECTOR SHELL, 4-place square terminal orientation, used on all of the following circuits listed below. Accepts the HCP24541TP round-pin female terminal only (does not accept original terminals). Each:
$ 8.95

* HCP24544MMWHT (the male shell) is used on:
- Left Handlebar Control Switch, on the switch lead-in harness: 1981-1983 XJ750 Seca models.
- Fusebox (in dash), on the main harness side of the connection: 1985-86 XJ700 all models and XJ750-X models.




HCP9334MNWHTNE Aftermarket white plastic MALE CONNECTOR SHELL, 4-place, rectangular, used on all of the following circuits listed below. Accepts the HCP9361xx female flat-blade terminal. Each:
$ 5.95

* HCP9334MNWHTNE (the male shell) is used on:
- Headlight Relay, on the main harness side of the connection: all XJ550 Seca, all XJ650 (except Turbo), 1982 XJ650RJ Seca, and 1981-83 XJ750 Seca models.
- Sidestand Relay, on the main harness side of the connection: all XJ550 Seca, 1982-84 XJ650 Maxim, 1982 XJ650RJ Seca, and 1981-83 XJ750 Seca models.
- Starting Circuit Cut-off Relay, on the main harness side of the connection: all XJ550 Seca, all XJ650 (except Turbo), 1982 XJ650RJ Seca, and 1981-83 XJ750 Seca models.
- TCI unit, ignition coils output side, on the main harness side of the connection: all XJ650 (except Turbo), 1981-83 all XJ750, and XJ1100 models



HCP9334MMWHTNE Aftermarket white plastic MALE CONNECTOR SHELL, 4-place, rectangular, with a male latching peg, used on all of the following circuits listed below. Accepts the HCP9361xx female flat-blade terminal. Each:
$ 5.95

* HCP9334MMWHTNE (the male shell with the male latching peg) is used on:
- Engine Emergency Stop Relay, on the main harness side of the connection: all XJ650 Turbo models.
- Fuel Pump Relay, on the main harness side of the connection: all XJ650 Turbo models.
- Headlight Relay, on the main harness side of the connection: all XJ550 Maxim models.
- Sidestand Relay, on the main harness side of the connection: all XJ550 Maxim, XJ650 Turbo, all XJ700, 1982-83 XJ750 Maxim and Midnight Maxim, XJ750-X, and XJ1100 models.
- Starting Circuit Cut-off Relay, on the main harness side of the connection: all XJ550 Maxim, XJ650 Turbo, 1982-83 XJ750 Maxim and Midnight Maxim, and XJ1100 models.
- TCI unit, pick-up coils output side, on the pick-up coils lead-in harness side of the connection: all XJ700 and XJ750-X models.




HCP9334MMBLKNE Aftermarket black plastic MALE CONNECTOR SHELL, 4-place, rectangular, with a male latching peg, used on all of the following circuits listed below. Accepts the HCP9361xx female flat-blade terminal. Each:
$ 5.95

* HCP9334MMBLKNE (the male shell with the male latching peg) is used on:
- Starting Circuit Cut-off Relay, on the main harness side of the connection: all XJ900 models.

NOTE: these same connectors were used on the following models, but were colored blue (instead of black); however, even though the blue connector shell is not currently available, these black shells can be used as an exact substitute in the following applications:

- Sidestand Relay, on the main harness side of the connection: all XJ900 models.





HCP9334FMWHT Aftermarket white plastic FEMALE CONNECTOR SHELL, 4-place, rectangular, with a male latching peg, used on all of the following circuits listed below. Accepts the HCP9360xx male flat-blade terminal. Each:
$ 5.95

* HCP9334FMWHT (the female shell with the male latching peg) is used on:
- Alternator stator lead harness, on the main harness side of the connection: all XJ1100 models. NOTE: the wires in the above circuit are 16-gauge, so choose your terminals appropriately.
- Main Key Switch lead-in harness, on the switch lead-in harness side of the connection: all XJ1100 models. NOTE: the wires in the above circuit are 14-gauge red, 14-gauge brown, and 18-gauge blue, so choose your terminals appropriately. Bikes that use the two red/white wires for the battery sensor have two additional 20-gauge wires.
- Main Key Switch lead-in harness, on the switch lead-in harness side of the connection: all XJ550 Euro (4V8) models, all XJ650 Euro (4K0 and 4K1 models), and some XJ750 Euro models (XJ750A and perhaps XJ750 E or E-II models).
- Regulator/Rectifier unit, on the main harness side of the connection: all XJ1100 models. NOTE: the wires in the above circuit are 20-gauge (x 2) and 14-gauge (x 2), and 16-gauge (x 3), so choose your terminals appropriately.
- TCI unit, ignition coils output side, on the main harness side of the connection: all XJ1100 models.
- Tail and License Plate Light harness, on the lights lead-in harness side of the connection: all 1981-83 XJ750 Seca models.





HCP9334MFWHTWE Aftermarket white plastic MALE CONNECTOR SHELL, 4-place, rectangular, with a female latch-peg receiver and side "ear" tabs, used on all of the following circuits listed below. Accepts the HCP9361xx female flat-blade terminal. Each:
$ 5.95

* HCP9334MFWHTWE (the male shell with the female latch-peg receiver and side "ear" tabs) is used on:
- Alternator stator lead harness, on the stator lead-in harness side of the connection: all XJ1100 models.
- Main Key Switch lead-in harness, on the main harness side of the connection: all XJ1100 models.
- Main Key Switch lead-in harness, on the main harness side of the connection: all XJ550 Euro (4V8) models, all XJ650 Euro (4K0 and 4K1 models), and some XJ750 Euro models (XJ750A and perhaps XJ750 E or E-II models).
- Regulator/Rectifier unit, on the regulator lead-in harness side of the connection: all XJ1100 models.
- Tail and License Plate Light harness, on the main harness side of the connection: all 1981-83 XJ750 Seca models.
- TCI unit, ignition coils output side, on the main harness side of the connection: all XJ550 models and XJ1100 models.






HCP9359MNOWTNE Aftermarket white plastic MALE CONNECTOR SHELL, 4-place, square, non-latching style, used on all of the following circuits listed below. Accepts the HCP9363BRD1418 or the HCP9363BRD1822 female flat-blade terminal. Each:
$ 5.95

* HCP9359MNOWTNE (the male shell) is used on:
- Dash Warning Lights (turn signals and hi-beam indicator) harness, on the dash light lead-in harness side of the connection: all 1982 XJ750 Maxim models.
- Dash Warning Lights harness, on the dash light lead-in harness side of the connection: all 1981-83 XJ750 Seca models.
- Dash Warning Lights (oil, hi-beam, and neutral indicator) harness, on the main harness side of the connection: all XJ900RK Seca models.
- Tachometer harness, on the tachometer lead-in harness side of the connection: all 1982-84 XJ650 Maxim, 1983-84 XJ750 Maxim and Midnight Maxim, and all XJ1100 models.
- Turn Signal Warning Lights (on dash) harness, on the warning lights harness side of the connection: all XJ550 Seca models.



HCP9359FNOWT Aftermarket off-white plastic FEMALE CONNECTOR SHELL, 4-place, square, non-latching style, used on all of the following circuits listed below. Accepts the HCP9362xx male flat-blade terminal. Each:
$ 5.95

* HCP9359FNOWT (the female shell) is used on:
- Dash Warning Lights (turn signals and hi-beam indicator) harness, on the main harness side of the connection: all 1982 XJ750 Maxim models.
- Dash Warning Lights harness, on the main harness side of the connection: all 1981-83 XJ750 Seca models.
- Dash Warning Lights (oil, hi-beam, and neutral indicator) harness, on the on the dash light lead-in harness side of the connection: all XJ900RK Seca models.
- Tachometer harness, on the main harness side of the connection: all 1982-4 XJ650 Maxim, 1983-84 XJ750 Maxim and Midnight Maxim, and XJ1100 models.

NOTE: this same connector was used on the following model, but is colored yellow (instead of off-white); however, even though the yellow connector shells are not currently available, these off-white shells can be used as an exact substitute in the following applications:

- Turn Signal Warning Lights (on dash) harness, on the main harness side of the connection: all XJ550 Seca models.




HCP9359FMWHT Aftermarket white plastic FEMALE CONNECTOR SHELL, 4-place, square, with a male latching peg, used on all of the following circuits listed below. Accepts the HCP9362xx male flat-blade terminal. Each:
$ 5.95

* HCP9359FMWHT (the female shell with the male latching peg) is used on:
- Left handlebar control switch turn signal circuit lead-in harness, on the switch lead-in harness side of the connection: all XJ700 models and the XJ750-X models.



HCP9359MFWHTWE Aftermarket white plastic MALE CONNECTOR SHELL, 4-place, square, with a female latch-peg receiver and side "ear" tabs, used on all of the following circuits listed below. Accepts only the HCP9363BR1812 or the HC9363TP1622 female flat-blade terminal. Each:
$ 5.95

* HCP9359MFWHTWE (the male shell with the female latch-peg receiver and side "ear" tabs) is used on:
- Left handlebar control switch turn signal circuit lead-in harness, on the main harness side of the connection: all XJ700 models and the XJ750-X models.

 

Six-terminal Connector Blocks:

HCP24545FFWHT Aftermarket white plastic FEMALE CONNECTOR SHELL, 6-place rectangle terminal orientation, used on all of the following circuits listed below. Accepts the HCP24540TP round-pin male terminal only (does not accept original terminals). Each:
$ 8.95

* HCP24545FFWHT (the female shell) is used on:
- Left Handlebar Control Switch, on the main harness side of the connection: XJ650 Turbo models, all XJ750 Maxim models, all XJ900 models, and XJ1100 models.
- Left Handlebar Control Switch, on the switch lead-in harness: all XJ550 models, and all XJ650 (except Turbo) models.



HCP24545MMWHT Aftermarket white plastic MALE CONNECTOR SHELL, 6-place rectangle terminal orientation, used on all of the following circuits listed below. Accepts the HCP24541TP round-pin female terminal only (does not accept original terminals). Each:
$ 8.95

* HCP24545MMWHT (the male shell) is used on:
- Left Handlebar Control Switch, on the switch lead-in harness: XJ650 Turbo models, all XJ750 Maxim models, all XJ900 models, and XJ1100 models.
- Left Handlebar Control Switch, on the main harness side of the connection: all XJ550 models, and all XJ650 (except Turbo) models.




HCP12881FMWHT Aftermarket white plastic FEMALE CONNECTOR SHELL, 6-place, trapezoidal, with dual male latching pegs, used on all of the following circuits listed below. Accepts the HCP9326xx male round pin terminal. Each:
$ 5.95

* HCP12881FMWHT (the female shell with the dual male latching pegs) is used on:
- Left handlebar control switch, on the control switch lead-in harness side of the connection: all XJ550 and all XJ650 (except Turbo) models.
- Left handlebar control switch, on the main harness side of the connection: all XJ650 Turbo, all 1981-83 XJ750 models, and XJ900 models.
- Left handlebar control switch, turn signal and horn lead-in harness, on the main harness side of the connection: all XJ1100 models.
- NOTE: this white connector shell cannot be used in place of the black or brown connector shell that is used on the right side handlebar control switch on all XJ-series models, as those shells are a slightly different size. The right side switch connector shells are not currently available.



HCP12881MFWHT Aftermarket white plastic MALE CONNECTOR SHELL, 6-place, trapezoidal, with a female latch-peg receiver and side "ear" tabs, used on all of the following circuits listed below. Accepts the HCP9327xx female "triangular" round style pin terminal. NOTE: some models used true "round pin" style terminals and a matching connector shell that is no longer available. These HCP12881MFWHT shells, when used with the replacement HCP9327 "triangular" round-style pins, will properly mate up with their opposite original shell on your bike. Each:
$ 5.95

* HCP12881MFWHT (the male shell with the female latch-peg receiver and side "ear" tabs) is used on:
- Left handlebar control switch, on the main harness side of the connection: all XJ550 and all XJ650 (except Turbo) models.
- Left handlebar control switch, on the control switch lead-in side of the connection: all XJ650 Turbo, all 1981-83 XJ750 models, and XJ900 models.
- Left handlebar control switch, turn signal and horn lead-in harness, on the control switch lead-in harness side of the connection: all XJ1100 models.
- NOTE: this white connector shell cannot be used in place of the black or brown connector shell that is used on the right side handlebar control switch on all XJ-series models, as those shells are a slightly different size. The right side switch connector shells are not currently available.





HCP9335FMWHT Aftermarket white plastic FEMALE CONNECTOR SHELL, 6-place, rectangular, with a male latching peg, used on all of the following circuits listed below. Accepts the HCP9360xx male flat-blade terminal. Each:
$ 5.95

* HCP9335FMWHT (the female shell with the a male latching peg) is used on:
- Computerized Dash Monitor lead-in harness, on the dash lead-in harness side of the connection: all XJ650 Turbo, 1982 XJ750 Maxim, 1981-83 XJ750 Seca, and XJ1100 models.
- Regulator-Rectifier lead-in harness, on the regulator lead-in harness side of the connection: all XJ1100 models.



HCP9335MFWHTWE Aftermarket white plastic MALE CONNECTOR SHELL, 6-place, rectangular, with a female latch-peg receiver and side "ear" tabs, used on all of the following circuits listed below. Accepts the HCP9361xx female flat-blade terminal. Each:
$ 6.95

* HCP9335MFWHTWE (the male shell with the female latch-peg receiver and side "ear" tabs) is used on:
- Computerized Dash Monitor lead-in harness, on the main harness side of the connection: all XJ650 Turbo, 1982 XJ750 Maxim, 1981-83 XJ750 Seca, and XJ1100 models.
- TCI Unit, on the pick-up coils lead-in harness, where it plugs into the TCI unit: all XJ550, XJ650 (except Turbo), and all 1981-83 XJ750 models.
- Regulator-Rectifier lead-in harness, on the main harness side of the connection: all XJ1100 models.





HCP9335MMWHTNE Aftermarket white plastic MALE CONNECTOR SHELL, 6-place, rectangular, with a male latching peg, used on all of the following circuits listed below. Accepts the HCP9361xx female flat-blade terminal. Each:
$ 6.95

* HCP9335MMWHTNE (the male shell with the male latching peg) is used on:
- TCI Unit, on the ignition coils side of the TCI, on the main harness side of the connection: all XJ700, XJ750-X, and all XJ900 models.






HCP9338FNOWT Aftermarket off-white plastic FEMALE CONNECTOR SHELL, 6-place, rectangular, used on all of the following circuits listed below. Accepts the HCP9362xx male flat-blade terminal. Each:
$ 5.95

* HCP9338FNOWT (the female shell) is used on:
- Turn signal Flasher Self-Canceller Unit lead-in harness, on the main harness side of the connection: all XJ550 models, all XJ650 models, all 1981-84 XJ750 models, all XJ900 models, and all XJ1100 models.

NOTE: this same connector is used on the following model, but is colored yellow (instead of off-white); however, even though the yellow connector shells are not currently available, these off-white shells can be used as an exact substitute in the following applications:

- Dash Warning Lights lead-in harness, on the main harness side of the connection: all XJ550 Seca and XJ1100 models.



HCP9338FNWHT Aftermarket white plastic FEMALE CONNECTOR SHELL, 6-place, rectangular, used on all of the following circuits listed below. Accepts the HCP9362xx male flat-blade terminal. Each:
$ 5.95

* HCP9338FNWHT (the female shell) is used on:
- Diode Block lead-in harness, on the diode block lead-in harness side of the connection: all XJ650 Turbo and XJ900 models.




HCP9338MNWHTNE Aftermarket white plastic MALE CONNECTOR SHELL, 6-place, rectangular, used on all of the following circuits listed below. Accepts the HCP9363BRD1822 or the HCP9363BRD1418 female flat-blade terminal. Each::
$ 6.95

* HCP9338MNWHTNE (the male shell) is used on:
- Diode Block lead-in harness, on the main harness side of the connection: all XJ650 Turbo and XJ900 models.
- Dash Warning Lights lead-in harness, on the warning lights lead-in harness side of the connection: all XJ1100 models.



HCP9338MNOWTNE Aftermarket off-white plastic MALE CONNECTOR SHELL, 6-place, rectangular, used on all of the following circuits listed below. Accepts the HCP9363BRD1822 or the HCP9363BRD1418 female flat-blade terminal. Each::
$ 6.95

* HCP9338MNOWTNE (the male shell) is used on:
- Turn signal Flasher Self-Canceller Unit lead-in harness, on the flasher lead-in harness side of the connection: all XJ550 models, all XJ650 models, all 1981-84 XJ750 models, all XJ900 models, and all XJ1100 models.

NOTE: this same connector is used on the following model, but is colored yellow (instead of off-white); however, even though the yellow connector shells are not currently available, these off-white shells can be used as an exact substitute in the following applications:

- Dash Warning Lights lead-in harness, on the warning lights lead-in harness side of the connection: all XJ550 Seca models.




Eight-terminal Connector Blocks:

HCP9336FMWHT Aftermarket white plastic FEMALE CONNECTOR SHELL, 8-place, rectangular, with a male latching peg, used on all of the following circuits listed below. Accepts the HCP9360xx male flat-blade terminal. Each:
$ 6.95

* HCP9336FMWHT (the female shell with the a male latching peg) is used on:
- Regulator-Rectifier lead-in harness, on the regulator lead-in harness side of the connection: all XJ-series (except 1100) models. NOTE: this shell can be used on the XJ1100 models if the molded male latch is removed. NOTE: the wires in the above circuit are 20-gauge (x 2) and 14-gauge (x 2), and 16-gauge (x 3), so choose your terminals appropriately.
- TCI unit, ignition coils output side, on the TCI lead-in harness side of the connection: all XJ650 Turbo models.



HCP9336MFWHTWE Aftermarket white plastic MALE CONNECTOR SHELL, 8-place, rectangular, with a female latch-peg receiver and side "ear" tabs, used on all of the following circuits listed below. Accepts the HCP9361xx female flat-blade terminal. Each:
$ 6.95

* HCP9336MFWHTWE (the male shell with the female latch-peg receiver and side "ear" tabs) is used on:
- Regulator-Rectifier lead-in harness, on the main harness side of the connection: all XJ-series (except 1100) models. NOTE: this shell can be used on the XJ1100 models if the molded female latch is removed. NOTE: the wires in the above circuit are 20-gauge (x 2) and 14-gauge (x 2), and 16-gauge (x 3), so choose your terminals appropriately.
- TCI unit, ignition coils output side, on the main harness side of the connection: all XJ650 Turbo models.




Nine-terminal Connector Blocks:

HCP9339FNWHT Aftermarket white plastic FEMALE CONNECTOR SHELL, 9-place, rectangular, used on all of the following circuits listed below. Accepts the HCP9362xx male flat-blade terminal. Each:
$ 6.95

* HCP9339FNWHT (the female shell) is used on:
- Dash Warning Lights (oil, hi-beam, neutral, and turn signal) harness, on the main harness side of the connection: all XJ550 Maxim, all XJ650 (except Turbo), and 1983 XJ750 Maxim and Midnight Maxim models.
- Dash Main Display lead-in harness, on the cluster lead-in harness side of the connection: all XJ650 Turbo models.
- Dash Main lead-in harness, on the cluster lead-in harness side of the connection: all XJ900 models.
- Speedometer harness, on the speedometer lead-in harness side of the connection: all 1982 XJ750 Maxim models.



HCP9339MNWHTNE Aftermarket white plastic MALE CONNECTOR SHELL, 9-place, square, used on all of the following circuits listed below. Accepts the HCP9363BRD1822 or the HCP9363BRD1418 female flat-blade terminal. Each:
$ 6.95

* HCP9339MNWHTNE (the male shell) is used on:
- Dash Warning Lights (oil, hi-beam, neutral, and turn signal) harness, on the dash light lead-in harness side of the connection: all XJ550 Maxim, all XJ650 (except Turbo), and 1983 XJ750 Maxim and Midnight Maxim models.
- Dash Main Display lead-in harness, on the main harness side of the connection: all XJ650 Turbo models.
- Dash Main lead-in harness, on the main harness side of the connection: all XJ900 models.
- Diode Block lead-in harness, on the main harness side of the connection: all XJ550 Seca, XJ700-X, and XJ750-X models.
- Speedometer harness, on the main harness side of the connection: all 1982 XJ750 Maxim models.

 

WIRE ASSEMBLY and SOLDERING TOOLS:

In order to properly attach a wire to another wire, or a wire to its end terminal, you will need to both CRIMP the wires together (or crimp the wire to the end terminal "arms"), and then apply SOLDER to the wire to insure both a mechanically strong and an electrically conductive connection. Additionally, you should apply either a SHRINK TUBE over the connection, or use a LIQUID ELECTRICAL TAPE sealer or wrap the connection with a VINYL ELECTRICAL TAPE product.

Remember, corrosion is the big enemy of electrical connectors, and everything you can do to prevent moisture from entering the bare wire joint will save you untold amounts of electrical grief down the road!

Of course, you'll need some professional-grade tools and supplies to produce professional-level results, starting with a precision WIRE CUTTER and STRIPPER TOOL, a WIRE TERMINAL CRIMPER TOOL, some low-temp SILVER SOLDER, and a SOLDERING GUN. We cannot over-emphasize that our experience shows that cheaply-made electrical system tools are simply not worth their "cheap" price....especially the wire crimper. The performance of the wire-to-terminal crimp is determined by the accuracy of the die profile of the tool jaws, and that's exactly where the cheap tool manufacturers cut corners. So don't scrimp on the crimp!


Terminal Removal Tools:

Once a wire-end terminal is inserted into its connector shell, a small metal "spring-tab" or "tongue" locks the terminal into a recess in the connector shell, thus preventing the terminal and wire from coming back out of the shell. Think of it as the terminal equivalent of the barb on the end of a fish-hook----easy going in, not so easy to get back out......

Of course, if you want or need to extract a terminal from its connector shell....for repair or replacement, for instance.....then you'll find the use of these TERMINAL REMOVAL TOOLS to be greatest thing since sliced bread. Proper width flat spring-steel blades formed into a rising wedge shape allows you to quickly and easily depress the spring-tab "hook" back up and into the terminal, thus "un-locking" the locking tab from the connector shell, and a quicky tug on the wire now releases the terminal from the shell. Works on all small, medium, and wide flat-blade style terminals only! Not for use on the round pin terminals.


HCP15686 Aftermarket small flat-blade TERMINAL REMOVAL TOOL, round plastic handle for ease of use.
$ 21.95

HCP15687 Aftermarket medium and large flat-blade TERMINAL REMOVAL TOOL, round plastic handle for ease of use. On some connector shells, this tool can also be used to release the small flat-blade terminals, too.
$ 21.95



Wire Cutter, Stripper, and Terminal Crimper Tools:

NOTE: SOME OF THE FOLLOWING TOOLS ARE AVAILABLE FOR RENTAL!!: some tools are a one-time or infrequent use tool, so it may be more economical for you to rent them from us, rather than to purchase outright. Please see the “rental” section within the THE TOOLBOX section of our catalog at:

http://xjbikes.com/forums/index.php?threads/xj-parts-catalog-section-p-the-toolbox.44630

and review the availability and procedures in the TOOL RENTAL section.


These professional-grade tools put the chain-store variety to shame. If you want strong and secure connections when you're done, don't try to save a few dollars on inferior quality tools. There's absolutely nothing more frustrating than have a wire stripper that pulls the wire strands out (along with the insulation) because it's pivot point won't hold a setting, or because the round holes were not cut to the proper depths. And terminal crimper tools that have an incorrect or poor tolerance profile just won't ever crimp tightly enough, and then the wire will pull out of the terminal crimp----no matter how hard you squeeze!


HCP13112 Aftermarket standard-duty WIRE CUTTER and STRIPPER TOOL. Designed for 10-22 gauge stranded copper wire only, this tool features precision-cut holes for wire insulation stripping, as well as high-carbon steel precision scissors-type blades for straight-cut, flush end wire cutting. Highly visible AWG and mm wire gauge sizes are embossed into the handle as well as color-coded. The tapered end of the base allows you to pull and twist frayed wire ends back into a tight strand. Soft comfort handles.
$ 29.95

HCP13113 Aftermarket heavy-duty WIRE CUTTER and STRIPPER TOOL. Designed for 12-20 gauge stranded copper wire only, this tool features precision-cut holes for wire insulation stripping, as well as stainless steel, nick-resistant scissors-type blades for straight-cut, flush end wire cutting. AWG wire gauge sizes are embossed into the handle. The tapered end of the base allows you to pull and twist frayed wire ends back into a tight strand. Curved, soft comfort-grip handles.
$ 49.95



HCP13223 Aftermarket heavy-duty WIRE CRIMPER, STRIPPER, and CUTTER TOOL, professional grade for use with original style "open-barrel" wire terminals. Although this crimper is not a ratchet-design, its long lever arms produce enough force to properly secure the wire to the terminal, vastly simplifying its use and performance. For 14-22 gauge wire terminals.
$ 129.95

HCP13065 Aftermarket heavy-duty WIRE CRIMPER TOOL, designed for use with original style "open-barrel" wire terminals. This crimper is a ratchet-design that will not release until the crimp is fully completed, vastly simplifying its use and performance. For 12-22 gauge wire terminals.
$ 79.95

HCP14583 Aftermarket super-duty WIRE CRIMPER TOOL, for use with original style "open-barrel" wire terminals. This crimper is a ratchet-design that will not release until the crimp is fully completed. For 12-22 gauge wire terminals. A professional level tool, combines ease of use while achieving crisp and consistent final crimp quality.
$ discontinued


HCP13066 Aftermarket heavy-duty WIRE CRIMPER TOOL, designed for use with aftermarket style "closed-barrel" wire terminals (such as with butt connectors, or other style terminals with a hollow metal receiver tube that the wire fits into before crimping). This crimper is also a ratchet-design that will not release until the die set if fully closed, and thus the crimp is fully completed. For 10-22 gauge wire terminals.
$ 69.95




Wire Solder and Soldering Guns:

While there is a unbelievably confusing array of solder choices, we've narrowed your choices down to one brand and type that we feel is the best: 3.5% SILVER BEARING, LEAD-FREE, ROSIN-CORE SOLDER. Let's go over those features one at a time:

a) Silver is the best material to use for small-wire electrical soldering, due to both the high-strength of silver and the exceptional electrical conductivity of silver (as opposed to lead-content solder).

b) Lead is a poisonous substance, and the soldering process has the potential to release lead fumes into the air....and into your eyes and lungs.....and that's just not a good thing, at all.

c) In the old days, solder was "pure" solder (be it lead-based, silver, etc.) and the cleaning flux was a separate material that had to be applied by hand. Modern "solder" is available with a central, internal flux core so that the cleaning and de-oxidizing properties of the flux----which has a lower melting point than the solder itself----is released first and performs the cleaning task on the wires and terminals immediately before the solder itself melts and flows. The miracles of modern technology at its best..........

NOTE: never use acid-core solder or an acid-based flux when performing electrical wire soldering! Acidic remnants of that type of flux will remain and eat away at your wires and terminals over time.


Of course, you'll want to apply such solder with a professional-quality SOLDER GUN, and since you probably, just like the rest of us, only have two hands, then you'll quickly come to appreciate our super-handy WIRE HOLDER tool that allows you to clamp the wires properly in place before soldering, leaving your hands free for the solder feed and the handling of the gun.


HCP13067 Aftermarket standard-duty SOLDERING GUN SET, 120-volt, dual 100-Watt and 140-Watts power settings, tip temperatures of 900-F and 1020-F. An excellent 8-piece kit which includes the gun, the tin-plated copper soldering tip, a plastics heat-cutting tip, a flux brush, all enclosed in a hard-shell protective carrying case.
$ 69.95

HCP13068 Aftermarket heavy-duty SOLDERING GUN SET, 120-volt, dual 200-Watt and 260-Watts power settings, tip temperatures of 900-F and 1100-F. An excellent 8-piece kit which includes the gun, the tin-plated copper soldering tip, a plastics heat-cutting tip, a flux brush, all enclosed in a hard-shell protective carrying case.
$ 89.95


HCP13108 Aftermarket 3.5% SILVER BEARING, LEAD-FREE, ROSIN-CORE SOLDER, 15-foot spool contains enough material to solder many, many wire joints! 430-F solder melt temperature, .032" diameter solder wire size is just right for the type of wires you'll be working on.
$ 19.95


HCP13111 Aftermarket magnetic WIRE HOLDER - CLAMPS TOOL, a very useful gadget when trying to manipulate 2 (or more) wires and trying to solder at the same time. Adjustable spring-loaded alligator clips hold the wires steady and in alignment while you do the soldering; both the tool base and the clips are magnetic so that you can the tool on a metal surface without it walking, or the hex-shaped tool base allows it to be clamped into a vice for complete restraint of movement. You'll be glad your bought it!
$ 29.95




Wire and Terminal Protection:

You have a few choices here, with the only rule being: choose one! Protecting the crimped and/or soldered bare wire connection from moisture and oxygen is the only way to keep it from corroding, which causes all sorts of un-fun problems with your electrical system.

The traditional method of sealing wire connections (wire-to-wire or wire-to-terminal) is to slather the finished joint generously with DI-ELECTRIC GREASE, and then, if space considerations permit, to cover the connection with either HEAT-SHRINK TUBE, ELECTRICAL TAPE, or both. "Electrical tape" in now available in both the traditional VINYL ELECTRICAL TAPE WRAP, or in a modern LIQUID ELECTRICAL TAPE form for ease of use and additional protection.

Shrink tubing shrinks tightly when heat is applied; we recommend the use of our HCP9809 flameless heat gun, or a small butane torch or even a lighter.....just make sure you apply the heat evenly over the entire surface. NOTE: always remember to install your shrink tubing over the wire before you install your wire end terminals!


NOTE that the very small flat spade terminals, pin terminals, and bullet terminals may not accept shrink tubing or electrical tape due to the small confines of their connector shells. In such situation, your best solution is to simply load up on the di-electric grease.......the more the merrier. It truly is advisable to fill the entire connector shell with di-electric grease to completely seal the wire, end terminals, and connection joint from any exposure to the atmosphere. Some people might consider this as anally-retentive behavior; we think of it as prudent.




HCP13030 Aftermarket wire harness STANDARD BLACK HEAT-SHRINK TUBING, a 2" length is just right for a wire-end to terminal joint or a butt connection. For use with 18-20 gauge wire. Each piece:
$ 1.25

HCP13036 Aftermarket wire harness DUAL-WALL BLACK HEAT-SHRINK TUBING, a 2" length is just right for a wire-end to terminal joint or a butt connection. This dual-wall design tubing contains an internal adhesive coating that melts and flows when the heat is applied, adding additional strength and protection to the finished installation. For use with 18-20 gauge wire. Each piece:
$ 1.50

HCP13033 Aftermarket wire harness STANDARD RED HEAT-SHRINK TUBING, this 2" length is just right for a wire-end to terminal joint or a butt connection. For use with 18-20 gauge wire. Each piece:
$ 1.25

HCP13038 Aftermarket wire harness DUAL-WALL RED HEAT-SHRINK TUBING, a 2" length is just right for a wire-end to terminal joint or a butt connection. This dual-wall design tubing contains an internal adhesive coating that melts and flows when the heat is applied, adding additional strength and protection to the finished installation. For use with 18-20 gauge wire. Each piece:
$ 1.50




HCP13031 Aftermarket wire harness STANDARD BLACK HEAT-SHRINK TUBING, a 2" length is just right for a wire-end to terminal joint or a butt connection. For use with 14-16 gauge wire. Each piece:
$ 1.25

HCP28307 Aftermarket wire harness DUAL-WALL BLACK HEAT-SHRINK TUBING, a 2" length is just right for a wire-end to terminal joint or a butt connection. This dual-wall design tubing contains an internal adhesive coating that melts and flows when the heat is applied, adding additional strength and protection to the finished installation. For use with 14-16 gauge wire. Each piece:
$ 1.50

HCP13034 Aftermarket wire harness STANDARD RED HEAT-SHRINK TUBING, this 2" length is just right for a wire-end to terminal joint or a butt connection. For use with 14-16 gauge wire. Each piece:
$ 1.25

HCP28308 Aftermarket wire harness DUAL-WALL RED HEAT-SHRINK TUBING, a 2" length is just right for a wire-end to terminal joint or a butt connection. This dual-wall design tubing contains an internal adhesive coating that melts and flows when the heat is applied, adding additional strength and protection to the finished installation. For use with 14-16 gauge wire. Each piece:
$ 1.50




HCP13032 Aftermarket wire harness STANDARD BLACK HEAT-SHRINK TUBING, a 2" length is just right for a wire-end to terminal joint or a butt connection. For use with 10-14 gauge wire. Each piece:
$ 1.25

HCP13037 Aftermarket wire harness DUAL-WALL BLACK HEAT-SHRINK TUBING, a 2" length is just right for a wire-end to terminal joint or a butt connection. This dual-wall design tubing contains an internal adhesive coating that melts and flows when the heat is applied, adding additional strength and protection to the finished installation. For use with 10-14 gauge wire. Each piece:
$ 1.50


HCP13035 Aftermarket wire harness STANDARD RED HEAT-SHRINK TUBING, this 2" length is just right for a wire-end to terminal joint or a butt connection. For use with 10-14 gauge wire. Each piece:
$ 1.25

HCP13039 Aftermarket wire harness DUAL-WALL RED HEAT-SHRINK TUBING, a 2" length is just right for a wire-end to terminal joint or a butt connection. This dual-wall design tubing contains an internal adhesive coating that melts and flows when the heat is applied, adding additional strength and protection to the finished installation. For use with 10-14 gauge wire. Each piece:
$ 1.50



HCP13040 Aftermarket wire harness DUAL-WALL BLACK HEAT-SHRINK TUBING, this 6" length is just right for battery terminal wire-end connections. This dual-wall design tubing contains an internal adhesive coating that melts and flows when the heat is applied, adding additional strength and protection to the finished installation. For use with 2-8 gauge battery or starter motor wire. Each piece:
$ 6.95

HCP13041 Aftermarket wire harness DUAL-WALL RED HEAT-SHRINK TUBING, this 6" length is just right for battery terminal wire-end connections. This dual-wall design tubing contains an internal adhesive coating that melts and flows when the heat is applied, adding additional strength and protection to the finished installation. For use with 2-8 gauge battery or starter motor wire. Each piece:
$ 6.95



HCP9809 Aftermarket 1100-F degree FLAMELESS HEAT GUN. This good quality, inexpensive heat gun is useful in a variety of situations. Great for helping to remove frozen carb and engine fasteners (it quickly heats up the metal surrounding the stuck fastener, helping to un-seize the fastener threads), applying electrical shrink tubing, removing decals and stripes, and other tasks. Two-speed/heat settings, 600-F and 1000-F. 120V. Can be used stand-alone with supporting clip or hand-held. Includes a air concentrator nozzle. For light-duty use only!
$ 59.95




Electrical System Chemicals and Supplies:

NOTE: it’s important to understand the difference between the two types of greases used with electrical connectors. Di-electric grease acts as an electrical insulator: it does not allow current to flow through it easily, and is basically used to “waterproof” a connector assembly. Although it is an insulator, the act of engaging two electrical connectors together (i.e. pushing a male connector into a female connector) will push away the grease on the metal-to-metal contact portion of the terminals, so those remain electrically conductive (good) while also insulating all the other surfaces against moisture and oxygen intrusion (very good). This insulating property of di-electric grease makes it great for use in connector shells, etc. as terminal corrosion is one of the greatest contributors to electrical system problems in vehicles (especially older ones)……this is why most modern vehicles use “sealed” connector shells (the most popular is the Delphi Automotive brand called “weather pack” or “weatherpak”) to keep oxygen and moisture away from the metal terminals. Although you can retrofit these style connectors to older harnesses, it takes a LOT of time, money, and effort to do so.

Now, contrast the insulating properties of di-electric grease to the electrically conductive properties of Conductive Grease, which, as its name implies, the grease itself (which contains many fine carbon particles) conducts electricity. Of course, being a “grease”, it too will also protect and insulate a terminal coated with it from moisture, corrosion, etc…..same as di-electric grease. But…it’s conductive, and if the terminal it coats is electrically “hot”, so is the grease (i.e. touching the grease alone will shock you!).

So a conductive grease is great when you need protection plus current flow……ideal for frame (or battery) grounds to the frame, etc. You could---if you are totally anally-retentive---coat (for instance) a battery post internally with conductive grease, and then cover all of that with di-electric grease.

So, think of these grease as two different electrical system “tools”, and use accordingly.


et2) Aftermarket electrical connector DI-ELECTRIC GREASE coats, insulates, and protects metal terminal connectors from exposure to air, thus preventing oxidation, the killer of electrical systems. Smear some of this goo on each and every one of your electrical connectors (after you've cleaned them with some sandpaper or terminal cleaner) and you'll be doing yourself a big favor!

HCP14059 Aftermarket packet of DI-ELECTRIC GREASE, single use 2-gram packet, enough to do a few light bulbs, terminals, etc.
$ 4.95

HCP7528 Aftermarket tube of DI-ELECTRIC GREASE, big 3-ounce squeeze tube.
$ 21.95

NOTE: the following 2 product(s) can only be shipped via ground transport (which thus eliminates the postal Priority Mail, postal Express Mail, or private carrier Expedited levels of service for this item) and cannot (and will not----don't even ask!) be shipped outside of the continental USA. Additionally, there may be a per-package weight or quantity restriction, and thus multiple-unit orders of this product may have to be shipped in separate packages and will incur additional shipping charges.

HCP20940 Aftermarket tube of DI-ELECTRIC GREASE, 3.3-ounce aerosol can of marine grade grease, with adjustable nozzle size to tailor the grease output bead size to minimize slop and waste and making application much easier. 1-2 cans will do all connectors on an entire bike harness.
$ 24.95



et14) Aftermarket electrical connector CONDUCTIVE GREASE coats and protects metal terminal connectors from exposure to air, thus preventing oxidation, the killer of electrical systems. Unlike the di-electric grease listed above, which is an insulator (non-conductive), this carbon-based grease is electrically conductive and has multiple applications (such as battery terminal posts (internally), frame grounds, etc.).

HCP27923 Aftermarket packet of CONDUCTIVE GREASE, single use 2-gram packet, enough to do a few light bulbs, terminals, etc. Even tiny amounts (that you can barely see) will create minimal electrical resistance, so be careful with this stuff around capacitors and such. It gets everywhere, will stain your hands and clothing and take three days to wash off, and smells like some of the worst goop you've ever smelled. Use a toothpick for application. Don't eat it. Wear gloves. 2-gram pouch goes a long way.
$ 6.95



cps2) Aftermarket high-quality CROCUS CLOTH. Unlike sandpaper or emery paper, crocus cloth is a super-fine, cloth-backed soft abrasive that doesn’t “shed” particles during use, and is just the thing for burnishing and polishing of copper electrical contact, like the alternator rotor and starter motor commutators. Sold in a 2” wide x 1-foot long strip, enough for polishing many a commutator or contact.

HCP21378 Aftermarket strip of CROCUS CLOTH, measures 12” x 2”. Each:
$ 4.95




NOTE: the following 3 product(s) can only be shipped via ground transport (which thus eliminates the postal Priority Mail, postal Express Mail, or private carrier Expedited levels of service for this item) and cannot (and will not----don't even ask!) be shipped outside of the continental USA. Additionally, there may be a per-package weight or quantity restriction, and thus multiple-unit orders of this product may have to be shipped in separate packages and will incur additional shipping charges.

HCP10493 Aftermarket battery post TERMINAL SEALER helps keep corrosion from forming on the battery terminals. Fast drying and leaves no residue. Comes in a 6-ounce aerosol can.
$ 12.95

HCP9762 Aftermarket miracle-goo black LIQUID ELECTRICAL TAPE is easier to use than traditional tape products, especially in close-in locations. Great for sealing crimped wire terminal ends to the wire and serves as a good alternative or supplement to shrink tubing. Just brush it on and let it dry! Comes in a 4-ounces brush-top can.
$12.95

HCP10508 Aftermarket electrical CONTACT CLEANER is a good general purpose cleaner and de-greaser. Will not harm plastic terminal connector blocks. Fast drying and leaves no residue. Comes in a 16-ounce aerosol can.
$ 14.95




HCP12923 Aftermarket harness bundle VINYL ELECTRICAL TAPE WRAP, black, 20-foot roll.
$ 8.95

HCP13134 Aftermarket harness bundle VINYL ELECTRICAL TAPE WRAP, black, 66-foot roll, almost enough to do one complete harness.
$ 16.95

Additionally, most harnesses had a few short turns of COLORED VINYL ELECTRICAL TAPE WRAP to provide visual identification of "what connector goes where?" during harness assembly and installation. Always located just by the connector shell, about 3-4 turns of this tape was used to both tape off any vinyl sleeve and to properly identify what the connector plugged into. Used primarily at the TCI connector (from the pick-up coils) and at the various small "cube" style relays (headlight relays, sidestand safety switch relays, etc.). Since all of these harness connector shells are the same style and type (4-position, horizontally oriented 2-over-2), this small tape wrap served as a way of indicating which of these many identical connectors went to which component.

HCP13130 Aftermarket harness bundle YELLOW VINYL ELECTRICAL TAPE WRAP, 20-foot roll. Used by the pick-up coil harness connector (at the TCI) on XJ700-X and XJ750-X models, and at the headlight relay connector on all XJ550 models, all XJ650 (except Turbo) models, and all XJ750 Seca models.
$ 7.95

HCP13131 Aftermarket harness bundle RED VINYL ELECTRICAL TAPE WRAP, 20-foot roll. Used by the pick-up coil harness connector (at the TCI) on 1982-83 XJ650 Maxim models, all '81-83 XJ750 models, and all XJ700 non-X models, and at the fuel pump relay connector on all XJ650 Turbo models.
$ 7.95

HCP13132 Aftermarket harness bundle BLUE VINYL ELECTRICAL TAPE WRAP, 20-foot roll. Used by the pick-up coil harness connector (at the TCI) on all XJ550 models, at the emergency stop switch relay connector on all XJ650 Turbo models, and for the sidestand safety switch relay connector on all XJ550 models, all '82-83 XJ650 models, all XJ750 models, XJ900RK and XJ1100 models.
$ 7.95

HCP13133 Aftermarket harness bundle GREEN VINYL ELECTRICAL TAPE WRAP, 20-foot roll. Used by the pick-up coil harness connector (at the TCI) on all XJ650RJ Seca and XJ1100 models.
$ 7.95





et26) Aftermarket electrical device SWITCH LUBRICANT is a specially formulated, electrically non-conductive penetrating lube that is recommended on control switch turn signal contacts and headlight switching contacts. 10-gram squeeze tube has applicator tip for precision use.

HCP14066 Aftermarket tube of electrical SWITCH LUBRICANT.
$ 16.95



et27) Aftermarket electrical INSTRUMENT OIL is a highly refined light oil for use on speedometer heads, tachometers, gauges, mechanical clocks, etc. Will not congeal even at 50-below-zero! Extra-slow rate of evaporation makes sure that it provides lubrication for a long, long time. 1-ounce pen has an applicator needle tip for precision use.

HCP20852 Aftermarket hi-performance INSTRUMENT OIL, comes in a handy applicator pen. Oil-based triple-processed lubricant eliminates contaminants that would cause gumming or corrosion product is what we use and recommend for freeing stuck fork tube cap bolts[/b][/color].
$ 37.95



HCP10540 Aftermarket acid-neutralizing BATTERY MAT, thin felt mat with pressure-treated with a battery-acid neutralizing chemical. Easily placed directly under the battery, it prevents any spills or discharge from the battery from doing damage to your paint, frame, etc. Trim to fit your battery box with a sharp knife or a pair of scissors. For all XJ550, XJ650, XJ700, XJ750, and XJ900RK models.
$ 9.95

HCP10541 Aftermarket acid-neutralizing BATTERY MAT, thin felt mat with pressure-treated with a battery-acid neutralizing chemical. Easily placed directly under the battery, it prevents any spills or discharge from the battery from doing damage to your paint, frame, etc. Trim to fit your battery tray with a sharp knife or a pair of scissors. For all XJ1100 models.
$ 13.95



HCP10580 Aftermarket acid-neutralizing BATTERY TERMINAL PROTECTORS, thin, round felt mat circles are pressure-treated with a battery-acid neutralizing chemical. Placed under the battery terminal posts, they help prevents any spills or discharge from the battery from creating terminal corrosion. Trim and size to fit your battery posts with a sharp knife or a pair of scissors. Order 1 per terminal, 2 per battery. Each:
$ 3.95



WIRE HARNESS CLIPS:

whc2) OEM wire harness wires, wire bundles, and control cable RETAINING CLIPS, CLAMPS, GROMMETS, AND BAND TIES help you to keep all the wires secure, routed correctly, and looking original. The various bands and ties are used in a variety of places throughout the bike frame, on the handlebars, and in other locations to help insure that things are kept out of harms way!


Grommets:

HCP2179 OEM tail light sub-harness GROMMET, oval "doughnut" wire lead grommet snaps into the hole near the tail light housing, and protects the tail light sub-harness where it enters before it goes under the rear fender. Use 1 on all of the following models: XJ550 Maxim, all XJ650 models (except XJ650RJ Seca), all XJ700 models, all XJ750 Maxim and Midnight Maxim, and all XJ1100 models. Each:
$ 7.95


HCP3455 OEM wire harness lead wire GROMMET, round "doughnut" wire lead grommet snaps into a hole near the front of the fender, and protects the tail light and turn signals sub-harness where it exit from under the rear fender. Use 1 on all of the following models: XJ550 Maxim, all XJ650 Maxim and Midnight Maxim models (except XJ650RJ Seca), and all XJ700 models. Each:
$ 5.95



Clips:

HCP3463 OEM tail light and rear turn signals sub-harness SNAP-OVER CLIP, pegged clip that snaps over itself the rear fender and then snaps shut over the top of the harness, near the front of the fender, and route the tail light and rear turn signal lead wires as they run forward along the top of the fender. Use 1 on all of the following models: all XJ650 models, all XJ700 models, and all XJ750 Seca models. Use 2 on all of the following models: all XJ900RK, RL, N/FN, and F models. Each:
$ 5.95

HCP3464 OEM tail light and rear turn signals sub-harness SNAP-OVER CLAMP, "U"-shaped clip is pegged into the rear inner fender and has an arm that snaps shut over the top of the harness, located near the front of the inner fender, and routes the tail light and rear turn signal lead wires as they run forward along the top of the fender. Use 1 on all of the following models: all FJ600, XJ650, and XJ750 models. Each:
$ 7.95

HCP8663 OEM tail light and rear turn signals sub-harness SNAP-OVER CLAMP, "U"-shaped clip is pegged into the rear inner fender and has an arm that snaps shut over the top of the harness, located near the front of the inner fender, and routes the tail light and rear turn signal lead wires as they run forward along the top of the fender. Use 3 on all of the following models: all XJ1100 models. Each:
$ 6.95



Clamps:

HCP3547 OEM main wire harness FRAME CLAMP, large double-armed, rubber-coated metal clamp supports and routes the main harness bundles near the steering tube. Use 1 on all XJ550 models. Each:
$ discontinued

HCP3548 OEM main wire harness FRAME CLAMP, smaller single open "c-hook" style, rubber-coated metal clamp supports and routes the main harness bundles near the steering tube. Use 2 on all XJ550 and FJ600 models. Each:
$ 5.95




Harness Band Ties:

Shaped like large, wide wire ties, but sporting a much wider shaft and an even wider T-head, these black serrated toothed "ratchet clamps" are used in a variety of both visible locations on each bike (such as on the handlebars) and in hidden locations (such as down by the kickstand switch) to properly retain control cables and wire harness leads. Although standard issue electrical-department-at-home-depot wire ties are similar, they are not nearly as wide as these original band ties, and especially for the visible locations, these original style ties provide that correct "detailed-restoration" look.


HCP3465 OEM black wire harness self-locking BAND TIE, 5" long by 5/16" wide, with large slotted T-head. Each:
$ 7.95

Used as follows:

XJ550 Maxim: 4 on the handlebars.
XJ550 Seca: 2 on the handlebars.
FJ600 (1986 models): 2 on the rear turn signal harness.

XJ650 Maxim/Midnight Maxim: 1 in the rear fender area, and 4 on the handlebars.
XJ650RJ Seca: 2 on the handlebars.
XJ650 Turbo: 2 on the handlebars.

XJ700 all models: 2 on the handlebars.
XJ750-X models: 2 on the handlebars.

1983 XJ750 Maxim/Midnight Maxim: 4 on the handlebars.




HCP3466 OEM black wire harness self-locking BAND TIE, 7" long by 3/8" wide, with large slotted T-head. Each:
$ 4.95

HCP18080 Aftermarket black wire harness self-locking BAND TIE, 7" long by 3/8" wide, with large slotted T-head. Each:
$ 3.95

The above straps are used as follows:

XJ550 Maxim: 5 on the main wire harness.
XJ550 Seca: 4 on the main wire harness.

FJ600 all: 3 on the main wire harness.

1980 XJ650 Maxim: 2 on the main wire harness.
1981-83 XJ650 all Maxim and Midnight Maxim: 2 on the main wire harness.
XJ650RJ Seca: 3 on the main wire harness.
XJ650 Turbo: 3 on the main wire harness, and 1 with the turbocharger "power-up kit" used optionally on 1982 models and on all 1983 models.

XJ700 all models: 2 on the main wire harness.
XJ750-X models: 2 on the main wire harness.

1981-83 XJ750 all models: 4 on the main wire harness.
XJ750 Seca models: 4 on the handlebars.

XJ900RK, RL, N/FN, and F models: 4-6 per bike, depending on specific model, on the main wire harness.

XJ1100: 4 on the main wire harness.




HCP3578 OEM black wire harness self-locking BAND TIE, 9" long by 3/8" wide, with large slotted T-head. Each:
$ 7.95

Used as follows:

1980-81 XJ650 Maxim/Midnight Maxim models: 2 on the main wire harness.
1982-83 XJ650 all Maxim models: 1 on the main wire harness.
XJ650RJ Seca models: 1 on the main wire harness.
XJ650 Turbo models: 1 on the main wire harness.

XJ700 all models: 1 on the main wire harness.
XJ750-X models: 1 on the main wire harness.

1981-83 XJ750 all models: 1 on the main wire harness.

XJ900RK, RL, and N/FN models: 1 on the main wire harness.

XJ1100 model: 1 on the main wire harness.

 

SECTION D:

ELECTRICAL SYSTEM:

--Charging System: Overview, AC Alternator/Generator, Regulator/Rectifier, and related.



CHARGING SYSTEM:

CHARGING SYSTEM OVERVIEW:

The following guide to understanding your charging system was contributed by Dwayne Verhey, extreme XJ-Wizard.

There are two main types of alternator systems commonly used on motorcycles. Both types depend on a magnetic field, created by magnets in the alternator rotor, to induce an electrical voltage and current flow in a stationary coil of wires-----the alternator stator. If you ever get confused as to which is which, just remember that the rotating component is the "rotating rotor", and the spaghetti-like bundle of wires is the fixed-in-place, "stationary stator"......

The first type is the permanent-magnet rotor system (used on Virago, V-max, and FJR models, among others). In these systems, the fixed-strength magnets in the spinning rotor generate a constant-strength magnetic field, and thus excite the stator coil constantly; thus the alternator puts out 100% current at all times and the voltage regulator merely serves to shunt any excess generated current to ground. The advantage of the permanent-magnet system is a reduced amount of system complexity, but at the cost of increased heat and power losses (since the alternator system is always generating maximum output, and thus using up engine horsepower, constantly).

The XJ-series of bikes follows the more common automotive model, which employs variable-strength electro-magnets in the rotor. In these systems, the variable-strength magnets in the spinning rotor, when energized, are used to form the magnetic field which excite the stator. The voltage regulator controls the voltage output by varying the input voltage applied to the rotor's electro-magnets, and thus varies the strength of the magnetic field. If the system voltage drops, the voltage regulator increases the voltage fed into the rotor electro-magnets, thus increasing the strength of the magnetic field that the magnets produce, and therefore increasing the excitation (output) from the stator....and thus the alternator output voltage increases. This type of system is more complex, but has the advantage of using less power to operate, thus freeing up engine output for more admirable purposes.

In both systems, the stator windings are 3-phase. Each stator wiring bundle (there are 3 of them, and each bundle is called a "leg") kicks out similar voltage, but 120-degrees out of phase with the adjacent leg(s). The resulting AC currents are then rectified (changed) to DC current via a 3-phase bridge rectifier, made up of 6 diodes, such that current in any leg flowing in either direction is directed back into the system as 12-volts DC (actually, around 13.5 to 14.5 volts DC, when everything is working properly).

If you lose a leg, or even a single diode, it is possible to still achieve voltage if the load is minimal, but as current requirements increase, the alternator will not be able to meet the challenge and the battery will have to take up the slack. Of course, as the battery drains, the available voltage is reduced, so the maximum rotor field voltage is reduced, so the current output is reduced, so the battery has to take up more slack, so ....

The end result is the battery discharges and the bike won't start.


If you suspect alternator issues, do the following checks, in this order:

- first check the resistance on the wires to the rotor. If resistances are out of spec, then check for dirty rotor commutator rings, corroded connections, etc.----all of these problems will reduce the available rotor field voltage.

- next, check the condition of the connectors from the stator to the rectifier (the 3 white wires). There's usually 2 connectors -- one from the alternator, often hidden behind the battery box, and the other near the regulator. Corrosion in these spots will reduce the stator's outputted current (bad corrosion will often melt the connector, as the outputted current turns into heat rather than being delivered to the battery).

- next, with the engine running, back-probe each of those 3 white wires at their connector to ensure voltage is being generated on each leg. NOTE: the voltage on those 3 white wires is AC, not DC, so be sure to set your voltmeter properly. AND, YOUR CHECK WILL BE BETWEEN WIRE PAIRS (wire #1 to #2, wire #2 to #3, and wire #1 to #3….and it doesn’t matter which one you consider wire #1 or #2 or #3 to be, as long as each wire’s output is checked)……AND NOT TO THE FRAME OR (GOD HELP YOU) TO THE BATTERY NEGATIVE. You should see some voltage (the actual amount is not meaningful, nor specified) on each test, and the voltages should be about the same on each leg.

- finally, using your multi-meter and following the directions in the service manual, check the function of each of the 6 diodes in the rectifier to make sure the power is being properly rectified from AC to DC.

 

Alternator Stator:

gp22) Aftermarket new or re-wound Alternator STATORS perfectly replace the originals. Rewound stator coils are sold on a "core charge" basis and you must return to us a usable, same-model stator core in order to receive your core charge refund. Re-wound stators will output at least the same current as an original stator, and comes with the wiring harness lead and connector but without the rubber insulator grommet that fits into the generator cover----so save your original grommet!

Checking alternator stators:

These tests should be taken while the components are at a temperature of about 70-F:

a) with the engine off and key off, measure the resistance across each pair of the three white wires (white1, white2, and white3) --- thus you take a separate measurement for white1 to white2, white1 to white3, and white2 to white3 ---- at the connector should be as follows. This test is measuring whether there is any internal short within each wire bundle.

0.50 ohms +/- 10% for all XJ550 models.

0.46 ohms +/- 10% for all XJ650, all XJ700, all XJ750, and XJ900RK models.

0.37 ohms +/- 10% for all XJ1100 models.

0.40 ohms +/- 10% for all XS1100 models.


b) with the engine off and key off, measure the continuity between each wire to ground (battery negative post or engine case, etc.). Thus white1 to ground, white2 to ground, and white3 to ground. This test is measuring whether there is any short within each wire bundle to the external world. There should not be any continuity.


c) with the engine running, back-probe each of those 3 white wires at their connector to ensure voltage is being generated on each leg. NOTE: the voltage on those 3 white wires is AC, not DC, so be sure to set your voltmeter properly. AND, YOUR CHECK WILL BE BETWEEN WIRE PAIRS (white1 to white2, white2 to white3, and white1 to white3….and it doesn’t matter which one you consider wire #1 or #2 or #3 to be, as long as each wire’s output is checked)……AND NOT TO THE FRAME OR (GOD HELP YOU) TO THE BATTERY NEGATIVE. You should see some voltage (the actual amount is not meaningful, nor specified) on each test, and the voltages should be about the same on each leg.


NOTE: for best performance, your alternator Stator and Rotor (or, the Field Coil on XS1100 models) should be replaced at the same time.



HCP4148 Aftermarket rebuilt/re-wound ALTERNATOR STATOR, with lead wire harness and connector, fits all XJ550, 1984-85 FJ600, and 1986-88 YX600 Radian models. A $ 50.00 core charge applies to this item, and a re-usable, same-model stator must be returned for the core charge to be refunded. NOTE: "re-usable" means it is complete and that none of the core ring plates are smashed or "separated" or splayed apart from each other.
$ 209.95 + $ 50.00 refundable core charge

HCP29211 Aftermarket brand new ALTERNATOR STATOR, with lead wire harness and connector, fits all 1989 YX600 Radian and 1989-91 XJ600 Euro models.
$ 169.95


HCP1679 Aftermarket rebuilt/re-wound 19-Amp ALTERNATOR STATOR, with lead wire harness and connector, fits all XJ650, XJ700 air-cooled, all XJ750 air-cooled, and XJ900RK, RL, N/FN, and F models. A $ 50.00 core charge applies to this item, and a re-usable, same-model stator must be returned for the core charge to be refunded. NOTE: "re-usable" means it is complete and that none of the core ring plates are smashed or "separated" or splayed apart from each other.
$ 169.95 + $ 50.00 refundable core charge

HCP17868 Aftermarket brand new 19-Amp ALTERNATOR STATOR, with lead wire harness and connector, fits all XJ650, XJ700 air-cooled, all XJ750 air-cooled, and XJ900RK, RL, N/FN, and F models.
$ 219.95


HCP19795 Aftermarket brand new 19-Amp ALTERNATOR STATOR, with lead wire harness and connector, fits all XJ600 Seca II models.
$ 229.95


HCP4149 Aftermarket rebuilt/re-wound 26-Amp ALTERNATOR STATOR, with lead wire harness and connector, fits all XJ700-X, XJ750-X, and XJ750P (24L and 37H) models. A $ 50.00 core charge applies to this item, and a re-usable, same-model stator must be returned for the core charge to be refunded. NOTE: "re-usable" means it is complete and that none of the core ring plates are smashed or "separated" or splayed from each other.
$ 239.95 + $ 50.00 refundable core charge


HCP4153 Aftermarket rebuilt/re-wound ALTERNATOR STATOR, with lead wire harness and connector, fits all XJ1100 models. A $ 50.00 core charge applies to this item, and a re-usable, same-model stator must be returned for the core charge to be refunded. NOTE: "re-usable" means it is complete and that none of the core ring plates are smashed or "separated" or splayed from each other.
$ 239.95 + $ 50.00 refundable core charge


HCP21758 Aftermarket rebuilt/re-wound ALTERNATOR STATOR, with lead wire harness and connector, fits all XS1100 models. A $ 50.00 core charge applies to this item, and a re-usable, same-model stator must be returned for the core charge to be refunded. NOTE: "re-usable" means it is complete and that none of the core ring plates are smashed or "separated" or splayed from each other.
$ 239.95 + $ 50.00 refundable core charge


HCP1462 OEM stator MOUNTING BOLT, black finish. Use 4 per stator on all XS1100 models to secure the stator to attach to cover.
$ 5.95

HCP2775 Aftermarket stator MOUNTING BOLT, 18-8 stainless steel with a bright finish. Use 4 per stator on all XS1100 models to secure the stator to attach to cover.
$ 2.95

HCP2787 Aftermarket stator MOUNTING BOLT, black-oxide coated alloy steel with self-locking threads. Use 4 per stator on all XS1100 models to secure the stator to attach to cover.
$ 2.95

HCP2788 Aftermarket stator MOUNTING BOLT, black-oxide coated alloy steel. Use 4 per stator on all XS1100 models to secure the stator to attach to cover.
$ 1.95



Alternator Rotors and Field Coils:

gp2) OEM new and aftermarket re-wound Alternator ROTORS perfectly replace the originals. Rewound rotors are sold on a "core charge" basis and you must return to us a usable, same-model rotor core in order to receive your core charge refund. Re-wound rotors will output at least the same current as an original.

Checking alternator rotors or field coil: the resistance across the two lead wires (usually brown and green) at the connector should be as follows. Note that worn or damaged alternator brushes can affect these readings, as can "dirty" copper commutator rings on the rotor face (where the brushes contact the rotor):

http://xjbikes.com/forums/index.php?threads/27387

4.5 ohms +/- 10% for all XJ550 models.

4.0 ohms +/- 10% for all XJ650, all XJ700, all XJ750, XJ900RK, and XJ1100 models.

3.5 ohms +/- 10% for all XS1100 models (field coil).


NOTE: for best performance, your alternator Stator and Rotor (or, the Field Coil on XS1100 models) should be replaced at the same time.


HCP4150 Aftermarket rebuilt/re-wound ALTERNATOR ROTOR, fits all 1982-83 XS400, XJ550, 1984-85 FJ600, and 1986-88 YX600 Radian models. A $ 50.00 core charge applies to this item, and a re-usable, same-model rotor must be returned for the core charge to be refunded. NOTE: "re-usable" means it is complete and has not been physically damaged in any way, the internal threads are not stripped, and the taper shaft bore is not gouged or distorted.
$ 209.95 + $ 50.00 refundable core charge


HCP465 OEM original, brand new 19-Amp ALTERNATOR ROTOR, fits all XJ650, XJ700 non-X, all XJ750 non-X, and XJ900RK, RL, N/FN, and F models.
$ 789.00

HCP4151 Aftermarket rebuilt/re-wound 19-Amp ALTERNATOR ROTOR, fits all XJ650, XJ700 non-X, all XJ750 non-X, and XJ900RK, RL, N/FN, and F models. A $ 50.00 core charge applies to this item, and a re-usable, same-model rotor must be returned for the core charge to be refunded. NOTE: "re-usable" means it is complete and has not been physically damaged in any way, the internal threads are not stripped, and the taper shaft bore is not gouged or distorted.
$ 209.95 + $ 50.00 refundable core charge


HCP4152 Aftermarket rebuilt/re-wound 26-Amp ALTERNATOR ROTOR, fits all XJ700-X, XJ750-X, and XJ750P (24L and 37H) models. A $ 50.00 core charge applies to this item, and a re-usable, same-model rotor must be returned for the core charge to be refunded. NOTE: "re-usable" means it is complete and has not been physically damaged in any way, the internal threads are not stripped, and the taper shaft bore is not gouged or distorted.
$ 229.95 + $ 50.00 refundable core charge


HCP4154 Aftermarket rebuilt/re-wound ALTERNATOR ROTOR, fits all XJ1100 models. A $ 50.00 core charge applies to this item, and a re-usable, same-model rotor must be returned for the core charge to be refunded. NOTE: "re-usable" means it is complete and has not been physically damaged in any way, the internal threads are not stripped, and the taper shaft bore is not gouged or distorted.
$ 239.95 + $ 50.00 refundable core charge



HCP21756 Aftermarket rebuilt/re-wound ALTERNATOR FIELD COIL, with lead wire harness and connector, fits all XS1100 models. A $ 50.00 core charge applies to this item, and a re-usable, same-model field coil unit must be returned for the core charge to be refunded. NOTE: "re-usable" means it is complete and that the wire harness has not been cut off.
$ 239.95 + $ 50.00 refundable core charge

HCP3150 OEM field coin assembly MOUNTING BOLT, to secure the field coil. Use 3 per coil, for all XS1100 models. Each:
$ 1.95



HCP2559 OEM alternator rotor flanged RETAINING BOLT, correct high-strength, wide flange hex bolt that holds the rotor onto the alternator shaft. Fits all 1982-83 XS400, XJ550, 1984-85 FJ600, 1986-88 FZ600, 1986-88 YX600 Radian, all XJ650, all XJ700, all XJ750, and all XJ900 models.
$ 9.95

HCP2560 OEM alternator rotor RETAINING BOLT, correct high-strength hex bolt that holds the rotor onto the alternator shaft. Fits all XJ1100 and XS1100 models.
$ 6.95



HCP2230 OEM alternator rotor retaining bolt LOCK WASHER, use with the above mounting bolt. Fits all XJ1100 and XS1100 models.
$ 7.95

HCP22225 Aftermarket alternator rotor retaining bolt LOCK WASHER, use with the above mounting bolt. Zinc-plated alloy steel. Fits all XJ1100 and XS1100 models.
$ 2.95

HCP22227 Aftermarket alternator rotor retaining bolt LOCK WASHER, use with the above mounting bolt. 18/8 stainless steel. Fits all XJ1100 and XS1100 models.
$ 3.95


HCP2562 OEM alternator rotor retaining bolt FLAT WASHER, use with the above mounting bolt. Fits all XJ1100 and XS1100 models.
$ 9.95



Alternator Rotor Removal Tools:

ap7) Aftermarket alternator ROTOR REMOVAL TOOLS, correct copy of the factory Yamaha tool needed to remove the alternator rotor from its mounting shaft (the rotor is a friction fit onto the tapered end of the alternator shaft). Designed to be used in conjunction with the HCP6495 rotor puller tool Attachment Tool listed below. The use of these two tools allows you to safely and properly remove your rotor without damaging either the rotor or the rotor shaft. For all XJ550, FJ600, XJ600 Seca II, XJ650, XJ700, XJ750, XJ900, and XJ1100 models.

If you find that you need to "lock" the rotor to prevent it from turning while tightening or loosening the retainer bolt, and don’t have the special Yamah “rotor locking tool” (which, honestly, no one has….), as an alternate solution you can put the bike in gear (preferably 5th) to lock the engine and tranny together, put the bike on the centerstand, and then slide a 2 x 4 (or something similar, but it’s preferrable that it’s something “soft” like wood)) thru the rear wheel spokes so that the ends of the 2 x 4 will eventually come to rest on the swingarm after the wheel rotates a distance…….in this way, the engine/transmission (and thus the rotor) are now locked together, and you can proceed to apply torque to the rotor bolt, which will eventually pop free (sometimes with a rather loud “bang!”) once the rear wheel locks itself in place

Or you can carefully employ this creative method of locking the rotor:

http://xjbikes.com/forums/index.php?threads/22765


NOTE: SOME OF THE FOLLOWING TOOLS ARE AVAILABLE FOR RENTAL!!: some tools are a one-time or infrequent use tool, so it may be more economical for you to rent them from us, rather than to purchase outright. Please see the “rental” section within the THE TOOLBOX section of our catalog at:

http://xjbikes.com/forums/index.php?threads/xj-parts-catalog-section-p-the-toolbox.44630

and review the availability and procedures in the TOOL RENTAL section.


HCP1404 Aftermarket ROTOR REMOVAL TOOL, screws into the threaded hub of the alternator, heavy-duty shop-grade tool.
$ 19.95

HCP21905 Aftermarket ROTOR REMOVAL TOOL, screws into the threaded hub of the alternator. Less expensive version than the shop-grade version tool HCP1404.
$ 14.95

HCP6495 Aftermarket ROTOR REMOVAL ATTACHMENT, slides into the end of the internally threaded alternator shaft and prevents the tip of the HCP1404 from "mushrooming" the end of the shaft.
$ 7.95




Alternator Brushes and Brush Holder Plate:

Replacing worn or oil-soaked ALTERNATOR BRUSHES is your first step towards a healthy, capable electrical system. We offer the both the brushes (individually or with their holders) or complete brush plate kits to allow you to quickly and easily fix any problems in this critical area.

Before you replace your alternator brushes, you should also check the condition of your alternator rotor and stator unit.

You can do this by following the instructions below; however, be aware that worn or dirty brushes CAN affect the resistance measurements for the ROTOR (as the rotor is what the brushes actually contact), so it may be useful to check the rotor resistance via attaching the ohmmeter test leads directly to the copper commutator strips on the rotor itself (as well as checking the resistance at the wire harness connector).

The alternator STATOR resistance tests should be taken at the wiring harness connector, although they can also be taken at the stator itself.

The factory resistance readings listed below do take into account the resistance of the wire harness leads between the component and the end of the harness lead wire; however, the wire harness resistance SHOULD BE minimal. If any out-of-spec readings are noted, it's best to take readings both at the component and then again at the end of the harness leads, and draw conclusions and follow-up procedures (i.e. cleaning the harness terminals, checking for pinched or burned wires in the harness, etc.) based on such information, and perhaps re-checking measurements after corrective actions are taken.


Checking alternator stators: the resistance across each pair (w1 to w2, w1 to w3, and w2 to w3) of the three white wires (w1, w2, and w3) at the alternator stator lead harness connector, on those three wires LEADING TO THE STATOR, should be as follows:

0.50 ohms +/- 10% for all XJ550 models.

0.46 ohms +/- 10% for all XJ650, all XJ700, all XJ750, and XJ900RK models.

0.37 ohms +/- 10% for all XJ1100 models.

0.40 ohms +/- 10% for all XS1100 models.


Checking alternator rotors: the resistance across the two lead wires (usually red and green) at the alternator rotor lead harness connector, on those two wire LEADING TO THE ROTOR, should be as follows. Note that worn or damaged alternator brushes can affect these readings, as can "dirty" copper commutator strips on the rotor face (where the brushes contact the rotor):

http://xjbikes.com/forums/index.php?threads/27387

4.5 ohms +/- 10% for all XJ550 models.

4.0 ohms +/- 10% for all XJ650, all XJ700, all XJ750, XJ900RK, and XJ1100 models.

3.5 ohms +/- 10% for all XS1100 models (field coil).


cps2) Aftermarket high-quality CROCUS CLOTH. Unlike sandpaper or emery paper, crocus cloth is a super-fine, cloth-backed soft abrasive that doesn't "shed" particles during use, and is just the thing for burnishing and polishing of copper electrical contact, like the alternator rotor and starter motor commutators. Sold in a 2" wide x 1-foot long strip, enough for polishing many a commutator or contact.

HCP21378 Aftermarket strip of CROCUS CLOTH, measures 12" x 2". Each:
$ 4.95



s7) Aftermarket ALTERNATOR BRUSHES WITH HOLDERS SET, matched pair of brushes with the metal holders and lead wires. NOTE: Alternator brushes should be replaced whenever they are less than 11mm in overall length......the factory maintenance interval indicates that you should expect to replace these brushes every 8-10,000 miles. Factory brushes have "wear marks" (scribed lines) on the brush to indicate their wear limit; these aftermarket brushes also have the scribed wear line. Overall length of these brushes are 17.10mm, with 9mm of length from the wear bars to the contact end of the brushes:

http://www.xjbikes.com/forums/threads/im-going-crazy.66888/page-4#post-466203

HCP215 Aftermarket ALTERNATOR BRUSHES WITH HOLDERS SET. Fits all 1982-83 XS400, XJ550, 1984-85 FJ600, 1986-88 FZ600, 1986-88 YX600 Radian, all XJ650, all XJ700, all XJ750, all XJ900, and XJ1100 models.
$ 29.95 set



abh9) OEM alternator BRUSH HOLDER PLATE, brown plastic plate that the alternator brushes actually attach to. Although this plate never "wears out", it may need replacing if you end up breaking it off while attempting to remove it. Includes the brush holder plate, both brushes, and the lead wires with the rubber generator cover grommet and the white plastic terminal connector. The appropriate hardware used to secure this plate to the generator cover is listed in the next section.

HCP471 OEM alternator BRUSH HOLDER PLATE, fits all XJ650, XJ700, XJ750, all XJ900RK, RL, N/FN, and F models, and XJ1100 models. NOTE: the lead wires differ in length between different models; the wires that come with this replacement unit may be slightly longer than your originals on all except the XJ1100 engines......the XJ1100 models used a much longer wire harness than what is provided on this brush plate, and the end connector is a different type. XJ1100 owners can use the brush plate and the brushes only----you will have to re-use your original lead harness.

Additionally, the molded rubber "dust seal" grommet on the wire harness is correct for all models except 700-X and 750-X models; the deeper cover on those models used a 1/4" longer grommet which is no longer available......so if you have a water-cooled model, you will have to carefully remove your original grommet and re-use it, or re-use your entire lead wire harness.
$ discontinued



abh7) Aftermarket ALTERNATOR BRUSHES HARDWARE, an assortment of the correct replacement screws and washers used to mount the brushes to the brush holder plate, and the brush holder plate to the alternator engine case cover.

NOTE: the large brush plate-to-engine case cover screws are VERY hard to remove.....they tend to "weld" themselves to the case. Please make sure that you use an appropriate size (large tip) JIS phillips screwdriver when attempting to remove them, as they will strip out quite easily. Then you're left with the task of trying to get those tight screws out from a small recessed area, and you run the risk of breaking the brush holder plate!

And, as always, when you go to replace these brush plate holder screws, make sure that you use some anti-seize compound on their threads!


HCP1030 OEM brush holder plate-to-cover SCREW, dark finish alloy steel, panhead, phillips drive. This is the large screw that is very difficult to remove. Originally it had a captured lock washer and flat washer, and was yellow-cad plated; these replacement screws come without the lock washer or the flat washer, which must be ordered separate below. Fits all XJ550, FJ600, XJ650, XJ700, XJ750, all XJ900RK, RL, N/FN, and F models, and XJ1100 models. Use 2 per bike. Each:
$ 7.95

HCP2922 Aftermarket brush holder plate-to-cover SCREW. This is the large screw that is very difficult to remove. Fits all XJ550, FJ600, XJ650, XJ700, XJ750, all XJ900RK, RL, N/FN, and F models, and XJ1100 models. Use 2 per bike. Zinc-plated alloy steel, natural finish, panhead phillips-drive, each:
$ 2.95

HCP21362 Aftermarket brush holder plate-to-cover SCREW. This is the large screw that is very difficult to remove. Fits all XJ550, FJ600, XJ650, XJ700, XJ750, all XJ900RK, RL, N/FN, and F models, and XJ1100 models. Use 2 per bike. 18/8 stainless steel, bright finish, panhead phillips-drive, each:
$ 3.95

HCP6714 Aftermarket brush holder plate-to-cover SCREW. This is the large screw that is very difficult to remove. Fits all XJ550, FJ600, XJ650, XJ700, XJ750, all XJ900RK, RL, N/FN, and F models, and XJ1100 models. Use 2 per bike. Button head hex-drive, 18-8 stainless steel, bright finish, each:
$ 3.95

HCP6715 Aftermarket brush holder plate-to-cover SCREW. This is the large screw that is very difficult to remove. Fits all XJ550, FJ600, XJ650, XJ700, XJ750, all XJ900RK, RL, N/FN, and F models, and XJ1100 models. Use 2 per bike. Socket head, hex-drive, black-oxide coated alloy steel, each:
$ 2.95

HCP6716 Aftermarket brush holder plate-to-cover SCREW. This is the large screw that is very difficult to remove. Fits all XJ550, FJ600, XJ650, XJ700, XJ750, all XJ900RK, RL, N/FN, and F models, and XJ1100 models. Use 2 per bike. Socket head, hex-drive, 18-8 stainless steel, bright finish, each:
$ 3.95




HCP315 OEM brush holder plate-to-cover LOCK WASHER, use 2 per unit. Fits all XJ550, FJ600, XJ650, XJ700, XJ750, all XJ900RK, RL, N/FN, and F models, and XJ1100 models. Each:
$ 3.95

HCP916 Aftermarket zinc-plated alloy steel with a natural finish, brush holder plate-to-cover LOCK WASHER, use 2 per unit. Fits all XJ550, FJ600, XJ650, XJ700, XJ750, all XJ900RK, RL, N/FN, and F models, and XJ1100 models. Each:
$ 1.95

HCP319 Aftermarket 18-8 stainless steel brush holder plate-to-cover LOCK WASHER, use 2 per unit. Fits all XJ550, FJ600, XJ650, XJ700, XJ750, all XJ900RK, RL, N/FN, and F models, and XJ1100 models. Each:
$ 2.95

HCP321 Aftermarket black oxide-coated alloy steel brush holder plate-to-cover LOCK WASHER, use 2 per unit. Fits all XJ550, FJ600, XJ650, XJ700, XJ750, all XJ900RK, RL, N/FN, and F models, and XJ1100 models. Each:
$ 1.95



HCP2173 OEM brush holder plate-to-cover FLAT WASHER, use 2 per unit. Fits all XJ550, FJ600, XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models, and XJ1100 models, original bright finish, each:
$ 2.95

HCP6642 Aftermarket brush holder plate-to-cover FLAT WASHER, zinc-plated alloy steel with a natural finish, use 2 per unit. Fits all XJ550, FJ600, XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models, and XJ1100 models, each:
$ 1.95

HCP6643 Aftermarket brush holder plate-to-cover FLAT WASHER, 18-8 stainless steel with a natural finish, use 2 per unit. Fits all XJ550, FJ600, XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models, and XJ1100 models, each:
$ 2.95

HCP25756 Aftermarket brush holder plate-to-cover FLAT WASHER, 316 stainless steel with a natural finish, use 2 per unit. Fits all XJ550, FJ600, XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models, and XJ1100 models, each:
$ 3.95

HCP14285 Aftermarket brush holder plate-to-cover FLAT WASHER, black oxide-coated 18-8 stainless steel, use 2 per unit. Fits all XJ550, FJ600, XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models, and XJ1100 models, each:
$ 2.95

HCP14284 Aftermarket brush holder plate-to-cover FLAT WASHER, black oxide-coated hardened alloy steel, use 2 per unit. Fits all XJ550, FJ600, XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models, and XJ1100 models, each:
$ 2.95



HCP4190 OEM brush holder-to-brush plate SCREW. This is the small screw that holds the brush metal bracket arm to the brush plate. Originally it had a captured lock washer and flat washer; these replacement screws come without the lock washer or the flat washer, which must be ordered separate below. Zinc-plated steel, panhead phillips-drive. Fits all XJ550, FJ600, XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models. Use 2 per bike. Each:
$ 6.95

HCP6418 Aftermarket brush holder-to-brush plate SCREW. This is the small screw that holds the brush metal bracket arm to the brush plate. Originally it had a captured lock washer and flat washer; these replacement screws come without the lock washer or the flat washer, which must be ordered separate below. Zinc-plated steel, panhead phillips-drive like original. Fits all XJ550, FJ600, XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models. Use 2 per bike. Each:
$ 1.95

HCP6421 Aftermarket brush holder-to-brush plate SCREW. This is the small screw that holds the brush metal bracket arm to the brush plate. Originally it had a captured lock washer and flat washer; these replacement screws come without the lock washer or the flat washer, which must be ordered separate below. Bright 18/8 stainless steel, panhead phillips-drive like original. Fits all XJ550, FJ600, XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models. Use 2 per bike. Each:
$ 2.95

HCP14239 Aftermarket brush holder-to-brush plate SCREW. This is the small screw that holds the brush metal bracket arm to the brush plate. Originally it had a captured lock washer and flat washer; these replacement screws come without the lock washer or the flat washer, which must be ordered separate below. Bright 18-8 stainless-steel, polished button head, hex- drive. Fits all XJ550, FJ600, XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models. Use 2 per bike. Each:
$ 2.95

HCP6422 Aftermarket brush holder-to-brush plate SCREW. This is the small screw that holds the brush metal bracket arm to the brush plate. Originally it had a captured lock washer and flat washer; these replacement screws come without the lock washer or the flat washer, which must be ordered separate below. Black-oxide coated 18/8 stainless steel, panhead phillips-drive like original. Fits all XJ550, FJ600, XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models. Use 2 per bike. Each:
$ 2.95

HCP6644 Aftermarket brush holder-to-brush plate SCREW. This is the small screw that holds the brush metal bracket arm to the brush plate. Originally it had a captured lock washer and flat washer; these replacement screws come with the lock washer but without the flat washer, which must be ordered separate below. Yellow zinc-plated steel, panhead phillips-drive like original. Fits all XJ550, FJ600, XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models. Use 2 per bike. Each:
$ 1.95



HCP326 OEM alloy-steel natural finish brush holder-to-brush plate screw LOCK WASHER, fits all XJ550, FJ600, XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models. Use 2 per bike. Each:
$ 3.95

HCP922 Aftermarket brush holder-to-brush plate screw LOCK WASHER, zinc-plated alloy steel, each:
$ 1.95

HCP336 Aftermarket brush holder-to-brush plate screw LOCK WASHER, 18-8 stainless-steel, each:
$ 2.95

HCP342 Aftermarket brush holder-to-brush plate screw LOCK WASHER, black oxide-coated steel, each:
$ 1.95



HCP328 OEM alloy-steel natural finish brush holder-to-brush plate screw FLAT WASHER, fits all XJ550, FJ600, XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models. Use 2 per bike. Each:
$ 3.95

HCP924 Aftermarket brush holder-to-brush plate screw FLAT WASHER, zinc-plated alloy steel, each:
$ 1.95

HCP338 Aftermarket brush holder-to-brush plate screw FLAT WASHER, 18-8 stainless-steel, each:
$ 2.95

HCP28050 Aftermarket brush holder-to-brush plate screw FLAT WASHER, grade 316 stainless-steel, each:
$ 3.95

HCP1356 Aftermarket brush holder-to-brush plate screw FLAT WASHER, black oxide-coated steel, each:
$ 1.95




Alternator Shaft:

The alternator rotor shaft is the same shaft that the starter motor drive operates. Where this shaft protrudes through the engine case, there is a bearing, a bearing housing, an o-ring for that housing, and an oil seal.....as well as three very special screws that hold the bearing housing to the engine case (you'll most likely need an impact driver tool, along with a properly fitting torx-screwdriver bit, to remove these screws).

IF YOU FIND ENGINE OIL IN THE ALTERNATOR CAVITY when you remove the alternator engine case outer cover.....well, then you'll need to replace the either the oil spray nozzle O-ring, and/or the shaft bearing housing O-ring and the Oil Seal, the housing screws, and just for precautionary measures, I would also recommend replacing the shaft Bearing while you've got everything this far apart.

NOTE: the alternator shaft bearing housing retaining screws HCP8492 listed below are special torx-drive screws, and require the use of an appropriate sized torx-drive socket or screwdriver. The original screws are installed with a thread-locking compound applied, and thus can be "frozen" in place and may require the use of heat to the surrounding engine case area (to expand the case slightly) and then may also require the use of an impact driver tool to break the screws loose. The screws should be re-installed with some semi-permanent thread-locking fluid applied.

HCP10236 Aftermarket TORX-DRIVE SOCKET, fits standard 3/8"-drive ratchets. Has the proper size torx-driver bit included. NOTE: this socket can be used with a 3/8" drive impact driver (such as our HCP9706 impact wrench set) but it is not rated for impact wrench use. However, since you will most likely only be using the bit one time (to loosen the 3 bearing housing screws), then you should be able to accomplish the task, and purchase a replacement bit if necessary.
$ 17.95

HCP10237 Aftermarket replacement TORX-DRIVE BIT, fits the above socket.
$ 5.95


Here's a good write-up on changing the alternator shaft oil seal on a later model Yamaha (XJ600 Seca II).....although the procedure is not exactly the same on the 1980's XJ-series engines, it's close enough to show the entire process, and with very good pictures:

http://www.xjrider.com/viewtopic.php?t=2101

And here is the procedure shown on an XJ700 engine, other XJ engines of this era are very similar in procedure:

http://www.xjbikes.com/forums/threads/replacing-alternator-seals-in-xj700n-with-pictures.108126/



And here’s some good videos showing the proper method of installing ball bearings into engine cases and onto shafts:



and





For all XJ550 models:

HCP11025 OEM alternator rotor SHAFT, brand new, includes the outer (left) bearing and the bearing housing O-ring, fits all XJ550 and 1984-85 FJ600 engines.
$ discontinued

HCP8612 OEM alternator shaft bearing HOUSING, brand new, fits all XJ550 and 1984-85 FJ600 engines.
$ 29.95

HCP8614 OEM alternator shaft bearing housing COVER PLATE, brand new, fits all XJ550 and 1984-85 FJ600 engines.
$ 29.95


HCP8492 OEM alternator bearing housing COUNTERSUNK SCREWS, use 3 per housing, torx-drive, fits all XJ550 and 1984-85 FJ600 engines. NOTE: these should be installed with 7.2 foot-pounds of torque. Each:
$ 7.95

HCP22177 Aftermarket alternator bearing housing COUNTERSUNK SCREWS, use 3 per housing, torx-drive, fits all XJ550 and 1984-85 FJ600 engines. NOTE: these should be installed with 7.2 foot-pounds of torque. Each:
$ 4.95



HCP8613 OEM alternator bearing housing O-RING, use 1 per engine, fits all XJ550, 1984-85 FJ600, 1986-87 FZ600, 1986-90 YX600 Radian, and 1992-98 XJ600 Seca II models.
$ 7.95

HCP14393 Aftermarket alternator bearing housing O-RING, original Buna-N material, use 1 per engine, fits all XJ550, 1984-85 FJ600, 1986-87 FZ600, 1986-90 YX600 Radian, and 1992-98 XJ600 Seca II models.
$ 4.95

HCP14394 Aftermarket alternator bearing housing O-RING, tougher Viton material, use 1 per engine, fits all XJ550, 1984-85 FJ600, 1986-87 FZ600, 1986-90 YX600 Radian, and 1992-98 XJ600 Seca II models.
$ 5.95


HCP8610 OEM alternator bearing shaft OIL SEAL, use 1 per engine, fits all XJ550, 1984-85 FJ600, 1986-88 FZ600, 1986-90 YX600 Radian, and 1992-98 XJ600 Seca II models.
$ 13.95

HCP8682 OEM alternator shaft O-RING, fits in-between the HCP8610 oil seal and the HCP8611 roller bearing, use 1 per engine, fits all XJ550, 1984-85 FJ600, 1986-90 YX600 Radian, and 1992-98 XJ600 Seca II models.
$ 7.95


HCP8611 OEM alternator shaft BEARING, left side (at bearing housing/rotor end of shaft), use 1 per engine, fits all XJ550, 1984-85 FJ600, and 1992-98 XJ600 Seca II models.
$ 54.95

HCP12765 OEM alternator shaft BEARING, right side (at end of alternator shaft, by starter clutch gear), use 1 per engine, fits all XJ550, 1984-85 FJ600, and 1992-98 XJ600 Seca II models.
$ 56.95

HCP19255 Aftermarket alternator shaft BEARING, right side (at end of alternator shaft, by starter clutch gear), use 1 per engine, fits all XJ550, 1984-85 FJ600, and 1992-98 XJ600 Seca II models.
$ 29.95



HCP8684 OEM alternator shaft PRIMARY DRIVE GEAR, right side (at end of alternator shaft, by starter clutch gear), 28-tooth, use 1 per engine, fits all XJ550 and 1984-85 FJ600 models.
$ 79.95

HCP8685 OEM alternator shaft LOCK WASHER, right side (at end of alternator shaft, retains the primary drive gear), use 1 per engine, fits all XJ550 and 1984-85 FJ600 models.
$ 5.95

HCP8686 OEM alternator shaft NUT, right side (at end of alternator shaft, retains the primary drive gear), use 1 per engine, fits all XJ550 and 1984-85 FJ600 models.
$ 8.95


HCP13969 OEM starter chain and guide OIL SPRAY NOZZLE, use 1 per engine, fits all XJ550, 1984-85 FJ600, 1986-88 FZ600, and 1986-90 YX600 Radian engines. O-ring is not included and should be ordered separate.
$ 139.95

HCP25652 OEM starter chain and guide OIL SPRAY NOZZLE, use 1 per engine, fits all 1992-98 XJ600 Seca II engines. O-ring is not included and should be ordered separate.
$ 44.95


HCP5400 OEM starter chain and guide oil spray nozzle O-RING, use 1 per engine, fits all XJ550, 1984-85 FJ600, 1986-88 FZ600, 1986-90 YX600 Radian, and 1992-98 XJ600 Seca II models.
$ 7.95

HCP20977 Aftermarket starter chain and guide oil spray nozzle O-RING, use 1 per engine, fits all XJ550, 1984-85 FJ600, 1986-88 FZ600, 1986-90 YX600 Radian, and 1992-98 XJ600 Seca II models.
$ 5.95





For all XJ650, XJ700, XJ750, and XJ900RK, RL, N/FN, and F models:

HCP8490 OEM alternator shaft bearing HOUSING, brand new, fits all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models.
$ 28.95



HCP8493 OEM alternator bearing housing COUNTERSUNK SCREWS, use 3 per housing, phillips-drive, fits all 1980-81 XJ650 Maxim models, each:
$ 7.95

HCP8492 OEM alternator bearing housing COUNTERSUNK SCREWS, use 3 per housing, torx-drive, for 1981 XJ650 Midnight Maxim models, all 1982-4 XJ650 models, all XJ700, all XJ750, and XJ900RK, RL, N/FN, and F models, each:
$ 7.95

HCP22177 Aftermarket alternator bearing housing COUNTERSUNK SCREWS, use 3 per housing, torx-drive, fits all XJ650, XJ700, XJ750, and XJ900RK, RL, N/FN, and F models. NOTE: these should be installed with 7.2 foot-pounds of torque. Each:
$ 4.95



NOTE: the HCP8492 and HCP8493 housing screws are identical in size and shape, and can be used interchangeably. The HCP8493 features a bright plated finish and has a phillips-drive screw slot, while the HCP8492 fastener features a dark oxide finish and uses a torx-drive head. They should be torqued to approximately 7.2 foot-pounds.


HCP8491 OEM alternator bearing housing O-RING, use 1 per engine, fits all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models:
$ 9.95

HCP14164 Aftermarket alternator bearing housing O-RING, original Buna-N material, use 1 per engine, fits all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models:
$ 7.95

HCP14165 Aftermarket alternator bearing housing O-RING, tougher Viton material, use 1 per engine, fits all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models:
$ 8.95


HCP8488 OEM alternator bearing shaft OIL SEAL, use 1 per engine, fits all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models. NOTE: the "open" side of this seal faces the engine!:
$ 14.95

HCP18145 Aftermarket alternator bearing shaft OIL SEAL, use 1 per engine, fits all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models. NOTE: the "open" side of this seal faces the engine!:
$ 9.95




HCP10232 OEM starter chain and guide OIL SPRAY NOZZLE, use 1 per engine, fits all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models. O-ring is not included and should be ordered separate.
$ 79.95

HCP26174 Aftermarket starter chain and guide OIL SPRAY NOZZLE, use 1 per engine, fits all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models. O-ring is not included and should be ordered separate.
$ 39.95



HCP10233 OEM starter chain and guide oil spray nozzle O-RING, use 1 per engine an all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F engines.
$ 7.95

HCP20976 Aftermarket starter chain and guide oil spray nozzle O-RING, use 1 per engine an all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F engines.
$ 5.95



HCP8487 OEM alternator shaft BEARING, left side (at bearing housing/rotor end of shaft), use 1 per engine, fits all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models:
$ 59.95

HCP19260 Aftermarket alternator shaft BEARING, left side (at bearing housing/rotor end of shaft), use 1 per engine, fits all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models:
$ 39.95

HCP8489 OEM alternator shaft BEARING, right side (at end of alternator shaft, by starter clutch gear), use 1 per engine, fits all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models:
$ 39.95



HCP11024 OEM alternator shaft END PLUG, right side (at end of alternator shaft, by starter clutch gear), use 1 per engine, fits all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models:
$ 5.95



For all XJ1100 models:

HCP12707 OEM primary shaft BEARING, left side, use 1 per engine on all XS1100 and XJ1100 models:
$ 29.95

HCP7848 OEM primary shaft BEARING, right side, use 1 per engine on all XJ1100 models:
$ 44.95



Generator (alternator rotor and stator) Covers, Gaskets, and Hardware:

ecc4) Engine GENERATOR COVER or alternator cover. Replacement covers, gaskets, and mounting hardware is listed below.

NOTE: if the threaded holes in the engine case have minor damage, they can be easily salvaged with a thread-chaser/tap:

HCP2399 Aftermarket THREAD CHASER AND CLEAN-UP TAP, made from a high-speed titanium nitride coated steel. For the following threaded holes listed below, as well as many other areas of the bike. This 6 x 1.00 pitch is a very common sized thread.
$ 19.95

- Hitachi HSC32 air compensator jet holes.
- Hitachi lower carb rack mount screw holes.
- Hitachi pilot and main air jets port holes (in carb throat, below vacuum piston).
- Hitachi carb bowl drain screw hole.
- All models: gas tank mounting holes for the petcock.
- All models: gas tank fuel sending unit mounting holes.
- Mikuni XJ550, FJ/FZ/YX600, XJ600 Seca Ii, XJ650 Turbo, XJ700-X, XJ750-X, XJ900, XJ1100, and XS1100 lower carb rack bracket screw holes.
- All XJ550 - XJ900 models cylinder head exhaust port stud holes.
- All XJ550 - XJ1100 models cylinder head valvecover mounting bolt holes.
- All XJ550 - XJ1100 and XS1100 models cylinder head cam bearing cap bolt holes.
- All XJ550 - XJ1100 and XS1100 models cylinder head intake manifold bolt holes.
- All XJ550 - XJ1100 and XS1100 models cylinder head valvecover mounting bolt holes.
- All XJ550 - XJ1100 and XS1100 models engine side covers mounting bolt holes.
- All XJ550 - XJ1100 and XS1100 models engine oil pan mounting bolt holes.
- All XJ550 - XJ1100 and XS1100 models engine upper-to-lower crankcase cinch bolt holes (note: some of the mounting holes are different size, and require the use of the larger HCP11028 tap below).
- XJ700-X and XJ750-X cylinder heads and jugs coolant jacket bolt holes.
- Some models: cylinder head cam chain tunnel-to-cylinder jugs cinching studs, for engines that have 2 studs on both the front and rear of the tunnel (models with a single tunnel stud use the HCP11028 tap listed further below).
- Most models: upper crankcase to cylinder jugs stud.
- All models: cam chain tensioner mounting bolt holes.
- Some models: mechanical tachometer drive housing mounting hole.
- exhaust headpipe gas test bolt threaded hole in the bottom of each header pipe.
- exhaust collector input (from header pipe) pinch clamp.
- collector chrome cover retaining bolt hole (XJ1100 models)
- collector chrome cover rear retaining screw hole (XJ1100 models).
- XJ650 Turbo models, turbo housing hole for the right muffler “joiner pipe” mounting bolt holes.


HCP28170 Aftermarket thread tap or EZ-out extractor TAP HANDLE, featuring offset tap handles and fully adjustable head for all m3-m12 size taps and size 0 to ½” extractors. This is the proper way to hold a tap or extractor to insure that the force is directed straight down and doesn’t “wobble” as you are cutting, reaming, or extracting. Much better than using pliers or vise-grips to hold the tool……..
$ 17.95


NOTE: always use a proper thread-cutting oil or lubricant before using thread taps! Thin motor oils work fine when merely doing a "clean-up" thread chase; a real cutting fluid should be obtained if a threaded bore needs to be truly cut:

NOTE: the following product(s) can only be shipped via ground transport (which thus eliminates the postal Priority Mail, postal Express Mail, or private carrier Expedited levels of service for this item) and cannot (and will not----don't even ask!) be shipped outside of the continental USA. Additionally, there may be a per-package weight or quantity restriction, and thus multiple-unit orders of this product may have to be shipped in separate packages and will incur additional shipping charges.


HCP2402 Aftermarket machinist-grade professional THREAD CUTTING FLUID, for use when cutting into aluminum or other soft metal. 4-ounce non-aerosol can.
$ 8.95

HCP2403 Aftermarket machinist-grade professional THREAD CUTTING FLUID, for use when cutting into steel or other ferrous metals. 4-ounce non-aerosol can.
$ 8.95




HCP1050 OEM engine GENERATOR COVER. Bright natural finish. Correct appearance for the following models: all XJ650 models, 1985 XJ700 non-X models, XJ750 Maxim models, 1981-82 XJ750 Seca, and all XJ900RL, N/FN, and F engines. NOTE: this cover will physically fit all of the following engines, but is only correct in finish and color for the models listed previously: "fits" all XJ650, XJ700 air-cooled, XJ750 air-cooled, and XJ900 engines. Brand new:
$ 179.95

HCP1051 OEM engine GENERATOR COVER. Black painted finish. Correct appearance for the following models: all XJ650RJ and RJC Seca and XJ650 Turbo models, NOTE: this cover will physically fit all of the following engines, but is only correct in finish and color for the models listed previously: "fits" all XJ650, XJ700 air-cooled, XJ750 air-cooled, and XJ900 engines. Brand new:
$ 189.95

HCP1052 OEM engine GENERATOR COVER. Glossy black painted finish. Correct for the following models: XJ650 Midnight Maxim, 1986 XJ700 air-cooled engines, and 1983-84 XJ750 Midnight Maxims. NOTE: this cover will physically fit all of the following engines, but is only correct in finish and color for the models listed previously: "fits" all XJ650, XJ700 air-cooled, XJ750 air-cooled, and XJ900 engines. Brand new:
$ 189.95

HCP1054 OEM engine GENERATOR COVER. Bright center with black painted rim. Correct for the following models: 1983 XJ750 Seca and XJ900RK models. Brand new:
$ 219.95



ec3) OEM Generator Cover-to-Block GASKET. A great idea to replace these anytime you remove the cover for periodic cleaning, testing, or brush replacement.

OEM generator cover gaskets are made from a standard duty, graphite impregnated paper material. We recommend the use of the aftermarket hi-performance paper gaskets which are designed to slightly swell in the presence of petroleum products (fuel or oil), thus creating a super-tight, leak-proof flange seal.

HCP1056 OEM generator cover METAL GASKET, fits all XJ550, 1986-88 FZ600, 1984-86 XJ600 Euro, and 1989-90 YX600 Radian models. NOTE: although never originally fitted to 1984-85 FJ600 and 1986-88 YX600 engines, this gasket will also fit those models and it is recommended that they be used.
$ 34.95

HCP17994 Aftermarket generator cover METAL GASKET, fits all XJ550, 1986-88 FZ600, and 1989-90 YX600 Radian models. NOTE: although never originally fitted to 1984-85 FJ600 and 1986-88 YX600 engines, this gasket will also fit those models and it is recommended that they be used.
$ 27.95

HCP18434 Aftermarket generator cover hi-performance PAPER GASKET, fits all XJ550, 1986-88 FZ600, and 1989-90 YX600 Radian models. This is a paper-style gasket, unlike the original metal gasket. NOTE: although never originally fitted to 1984-85 FJ600 and 1986-88 YX600 engines, this gasket will also fit those models and it is recommended that they be used.
$ 29.95



HCP1057 OEM generator cover standard duty paper GASKET, fits all XJ650, XJ700 non-X, 1981-83 XJ750 models, XJ750RL, and all XJ900RK, RL, N/FN, and F models. NOTE: XJ700-X and XJ750-X (water-cooled) models originally used a metal gasket in this location, which is no longer available, and this paper gasket will serve as a suitable replacement.
$ 28.95

HCP18435 Aftermarket generator cover hi-performance GASKET, fits all XJ650, XJ700 non-X, 1981-83 XJ750 models, XJ750RL, and all XJ900RK, RL, N/FN, and F models. NOTE: XJ700-X and XJ750-X (water-cooled) models originally used a metal gasket in this location, which is no longer available, and this paper gasket will serve as a suitable replacement.
$ 29.95


HCP1059 OEM generator cover standard duty paper GASKET, fits all XJ1100 and XS1100 models.
$ 34.95

HCP18437 Aftermarket generator cover hi-performance GASKET, fits all XJ1100 and XS1100 models.
$ 29.95




cm72) OEM and aftermarket Generator Cover MOUNTING HARDWARE. Original style allen head, hex-drive bolts offered in both original and replacement style.


For all XJ550, FJ600, XJ650, XJ700, XJ750, and XJ900 models:


HCP1041 OEM generator cover MOUNTING BOLT, allen head hex-drive, natural finish. Uses 3 per cover. Correct finish for all XJ550, XJ650 Maxim, 1985 XJ700 non-X, 1981-82 XJ750 Seca, 1982-83 XJ750 Maxim, and XJ900RL, N/FN, and F models. Each:
$ 8.95

HCP1041SET3 OEM generator cover MOUNTING BOLTS, set of 3:
$ 24.95



HCP1061 OEM generator cover MOUNTING BOLT, allen head hex-drive, black finish. Uses 3 per cover. Correct finish for all 1984-85 FJ600, 1986-88 FZ600, 1986-90 YX600 Radian, XJ650 Midnight Maxim, XJ650RJ Seca, XJ650 Turbo, 1986 XJ700 non-X, all XJ700-X and XJ750-X, 1983 XJ750 Seca, XJ750 Midnight Maxim, and XJ900RK models. Each:
$ 5.95

HCP1061SET3 OEM generator cover MOUNTING BOLTS, set of 3:
$ 16.95



HCP222 Aftermarket generator cover MOUNTING BOLT, allen head hex-drive, 18-8 stainless steel bright finish. Uses 3 per cover. Fits all XJ550, FJ600, XJ650, XJ700, XJ750, and XJ900 models. Each:
$ 2.95

HCP222SET3 Aftermarket generator cover MOUNTING BOLTS, set of 3:
$ 7.95



HCP223 Aftermarket generator cover MOUNTING BOLT, allen head hex-drive, black-oxide coated finish. Uses 3 per cover. Fits all XJ550, FJ600, XJ650, XJ700, XJ750, and XJ900 models. Each:
$ 1.95

HCP223SET3 Aftermarket generator cover MOUNTING BOLTS, set of 3:
$ 5.75



For all XJ1100 and XS1100 models:

NOTE: XJ1100 and XS1100 models used a total of 5 bolts to retain the generator cover, 3 long bolts and 2 shorter bolts, and 2 locating dowel pins.


HCP1043 OEM generator cover LONG MOUNTING BOLT, allen head hex-drive, zinc-plated. Fits all XJ1100, XS1100 Standard, and XS1100 Special models, use 3 per cover. Each:
$ 7.95

HCP1043SET3 OEM generator cover LONG MOUNTING BOLTS, set of 3:
$ 22.95


HCP966 OEM generator cover SHORT MOUNTING BOLT, alloy-steel, zinc-plated allen head hex-drive screw. Fits all XJ1100, XS1100 Standard, and XS1100 Special models, use 2 per cover. Each:
$ 7.95

HCP966SET2 OEM generator cover SHORT MOUNTING BOLTS, set of 2:
$ 14.95



HCP9596 OEM generator cover LONG MOUNTING BOLT, allen head hex-drive, black finish. Fits all XS1100 Midnight Special models, use 3 per cover. Each:
$ 4.95

HCP9596SET3 OEM generator cover LONG MOUNTING BOLTS, set of 3:
$ 12.95



HCP971 OEM generator cover SHORT MOUNTING BOLT, allen head hex-drive, black finish. Fits all XS1100 Midnight Special models, use 2 per cover. Each:
$ 7.95

HCP971SET2 OEM generator cover SHORT MOUNTING BOLTS, set of 2:
$ 14.95



HCP26503 Aftermarket generator cover LONG MOUNTING BOLT, alloy-steel, zinc-plated allen head hex-drive screw. Fits all XJ1100 and XS1100 models, use 3 per cover. Each:
$ 1.95

HCP26503SET3 Aftermarket generator cover LONG MOUNTING BOLTS, set of 3:
$ 5.75


HCP22253 Aftermarket generator cover SHORT MOUNTING BOLT, alloy-steel, zinc-plated allen head hex-drive screw. Fits all XJ1100 and XS1100 models, use 2 per cover. Each:
$ 1.95

HCP22253SET2 Aftermarket oil pump covers MOUNTING BOLTS, set of 2:
$ 2.95


HCP2786 Aftermarket generator cover LONG MOUNTING BOLT, allen head hex-drive, black-oxide coated alloy steel. Fits all XJ1100 and XS1100 models, use 3 per cover. Each:
$ 1.95

HCP2786SET3 Aftermarket generator cover LONG MOUNTING BOLTS, set of 3:
$ 5.75


HCP228 Aftermarket generator cover SHORT MOUNTING BOLT, allen head hex-drive, black-oxide coated steel. Fits all XJ1100 and XS1100 models, use 2 per cover. Each:
$ 1.95

HCP228SET2 Aftermarket generator cover SHORT MOUNTING BOLT, set of 2:
$ 2.95


HCP2782 Aftermarket generator cover LONG MOUNTING BOLT, allen head hex-drive, black-oxide coated steel, self-locking threads. Fits all XJ1100 and XS1100 models, use 3 per cover. Each:
$ 2.95

HCP2782SET3 Aftermarket generator cover LONG MOUNTING BOLTS, set of 3:
$ 7.95


HCP2779 Aftermarket generator cover SHORT MOUNTING BOLT, allen head hex-drive, black-oxide finish, features self-locking threads. Fits all XJ1100 and XS1100 models, use 2 per cover. Each:
$ 2.95

HCP2779SET2 Aftermarket generator cover SHORT MOUNTING BOLTS, set of 2:
$ 4.95


HCP1242 Aftermarket generator cover LONG MOUNTING BOLT, allen head hex-drive, 18-8 stainless steel, bright finish. Fits all XJ1100 and XS1100 models, use 3 per cover. Each:
$ 2.95

HCP1242SET3 Aftermarket generator cover LONG MOUNTING BOLTS, set of 3:
$ 7.95


HCP226 Aftermarket generator cover SHORT MOUNTING BOLT, allen head hex-drive, 18-8 stainless steel, bright finish. Fits all XJ1100 and XS1100 models, use 2 per cover. Each:
$ 2.95

HCP226SET2 Aftermarket generator cover SHORT MOUNTING BOLTS, set of 2:
$ 4.95




HCP968 OEM generator cover locating DOWEL PIN , use 2 per cover. For all XJ1100 and all XS1100 models. Each:
$ 7.95





Regulator/Rectifier and Related:

er2) OEM and Aftermarket REGULATOR - RECTIFIER----this is the ribbed aluminum box with the multi-wire plug attached. Regulates the voltage from the alternator, and changes it ("rectifies") from AC to DC.

There are a number of different tests that can be performed on the regulator and rectifier unit, and it is beyond the scope of this catalog to explain in detail what those tests are, and when and how to perform them. The regulator, in particular, stands "in-between" two of the main electrical components in the entire system----the battery and the alternator----and thus performance of those components must be evaluated before a faulty regulator is suspected. We strongly suggest the purchase of a factory or aftermarket service manual for your bike to be able to properly diagnose and perform electrical system problem solving and repairs!

This guide is pretty good basic how-to synopsis of all the tests that the factory service manual recommends when testing the regulator side of the regulator/rectifier unit (step 1) and the rectifier section of the regulator/rectifier unit (step2):

http://www.xjcd.org/750RH_charging



Regulator - Rectifier Units:

HCP408 OEM factory REGULATOR - RECTIFIER, fits all 1982-83 XS400, XJ550, 1984-85 FJ600, 1986-90 YX600 Radian, XJ650, XJ700, XJ750, and XJ900RK, RL, N/FN, and F models. NOTE: the lead wires coming off the rectifier have the wires arranged in a different order than the stock unit, but the wires ARE color-coded and clocked correctly into the original-style 8-space white plastic harness connector.....so it is a plug-in direct replacement, no mods are necessary!
$ discontinued

HCP1678 Aftermarket replacement REGULATOR - RECTIFIER, fits all 1982-83 XS400, XJ550, 1984-85 FJ600, 1986-90 YX600 Radian, XJ650, XJ700, XJ750, and XJ900RK, RL, N/FN, and F models. Made by the original Yamaha supplier. NOTE: the lead wires coming off the rectifier have the wires arranged in a different order than the stock unit, but the wires ARE color-coded and clocked correctly into the original-style 8-space white plastic harness connector.....so it is a plug-in direct replacement, no mods are necessary!
$ 109.95


HCP19747 Aftermarket replacement REGULATOR - RECTIFIER, fits all 1992-96 XJ600 Seca II models. Made by the original Yamaha supplier.
$ 89.95



HCP4147 Aftermarket replacement REGULATOR - RECTIFIER, fits all XJ1100 models. NOTE: this is a generic style regulator/rectifier unit that has the proper electrical specifications for these models. It comes with the lead wires but no harness connectors.....so you will have to order the terminal connectors below separate!
$ 119.95

HCP9335FMWHT Aftermarket white plastic FEMALE CONNECTOR SHELL, 6-place, rectangular, with a male latching peg, used on the XJ1100 regulator lead-in harness. Accepts the HCP9360xx male flat-blade terminal. Each:
$ 4.95

HCP9336FMWHT Aftermarket white plastic FEMALE CONNECTOR SHELL, 8-place, rectangular, with a male latching peg, can be used on the XJ1100 models if the molded male latch is removed. Accepts the HCP9360xx male flat-blade terminal. Each:
$ 5.95

HCP9360BR1418 Aftermarket "medium-width" straight MALE MEDIUM BRASS FLAT BLADE WIRE-END TERMINAL, correct style solid brass terminal features a retention tab for insertion and positive locking into their connector shell. Accepts 14-18 gauge wires. Each:
$ 1.95


HCP21751 Aftermarket replacement REGULATOR - RECTIFIER, fits all XS1100 models. NOTE: the lead wires coming off the rectifier have the wires arranged in a different order than the stock unit, but the wires ARE color-coded and clocked correctly into the original-style 8-space white plastic harness connector.....so it is a plug-in direct replacement, no mods are necessary
$ 169.95



Voltage Regulator ID Decals:

HCP15163 Aftermarket voltage regulator case ID DECAL, red foil decal with the brushed silver 12R-A0 wording. Used on the 1981-86 FJ600, XJ650, XJ700, XJ750, and XJ900 models.
$ 11.95

HCP15164 Aftermarket voltage regulator case ID DECAL, red foil decal with the brushed silver 10M-A0 wording. Used on the 1982-84 XJ1100 models.
$ 11.95



Regulator - Rectifier Mounting Hardware:

er5) All of the little SCREWS, WASHERS, & NUTS needed to properly mount the regulator-rectifier and TCI units to their plastic foundation (which called the "bridge plate").

HCP4251 OEM regulator-rectifier mounting SCREW, use 2 per unit. Fits all XJ550, FJ600, XJ650 (except Turbo) models, all 1985 XJ700 N/NC models, all XJ750 models, and all XJ1100 models. Each:
$ 7.95

HCP4252 OEM regulator-rectifier mounting SCREW, use 2 per unit. Fits all 1986 XJ700 (except N/NC) models. Each:
$ 3.95


HCP3926 OEM regulator-rectifier mounting SCREW, alloy steel, panhead, phillips-drive, black finish. Use 2 per unit. Fits all XJ650 Turbo models. Each:
$ 7.95

HCP3114 Aftermarket regulator-rectifier mounting SCREW, alloy steel, panhead, phillips-drive, bright finish. Use 2 per unit. Fits all XJ650 Turbo models. Each:
$ 1.95

HCP3115 Aftermarket regulator-rectifier mounting SCREW, 18-8 stainless steel, panhead, phillips-drive, bright finish. Use 2 per unit. Fits all XJ650 Turbo models. Each:
$ 2.95

HCP26199 Aftermarket regulator-rectifier mounting SCREW, 316 stainless steel, panhead, phillips-drive, black finish. Use 2 per unit. Fits all XJ650 Turbo models. Each:
$ 3.95



HCP4255 OEM regulator-rectifier mounting BOLT, use 2 per unit. Alloy steel hex-head bolt with a bright finish. Fits all XJ900RK, RL, N/FN, and F models. Each:
$ 2.95

HCP27641 Aftermarket regulator-rectifier mounting BOLT, use 2 per unit. Alloy steel hex-head bolt with a bright zinc-plated finish. Fits all XJ900RK, RL, N/FN, and F models. Each:
$ 1.95



HCP315 OEM regulator-rectifier mounting LOCK WASHER, use 2 per unit. Fits all XJ550, FJ600, XJ650, XJ750, all XJ900RK, RL, N/FN, and F models, and XJ1100 models. Each:
$ 3.95

HCP916 Aftermarket zinc-plated alloy steel with a natural finish, regulator-rectifier mounting LOCK WASHER, use 2 per unit. Fits all XJ550, FJ600, XJ650, XJ750, all XJ900RK, RL, N/FN, and F models, and XJ1100 models. Each:
$ 1.95

HCP319 Aftermarket 18-8 stainless steel regulator-rectifier mounting LOCK WASHER, use 2 per unit. Fits all XJ550, FJ600, XJ650, XJ750, all XJ900RK, RL, N/FN, and F models, and XJ1100 models. Each:
$ 2.95

HCP321 Aftermarket black oxide-coated alloy steel regulator-rectifier mounting LOCK WASHER, use 2 per unit. Fits all XJ550, FJ600, XJ650, XJ750, all XJ900RK, RL, N/FN, and F models, and XJ1100 models. Each:
$ 1.95



HCP2173 OEM regulator-rectifier mounting FLAT WASHER, use 2 per unit. Fits all XJ550, 1984-85 FJ600, XJ650, XJ750, and all XJ900RK, RL, N/FN, and F models, original bright finish, each:
$ 2.95

HCP1869 OEM regulator-rectifier mounting screw FLAT WASHER, use 2 per unit. Fits all XJ700 and XJ750-X models, black-oxide finish, each:
$ 2.95

HCP6642 Aftermarket regulator-rectifier mounting screw FLAT WASHER, zinc-plated alloy steel with a bright finish, use 2 per unit. Fits all XJ550, 1984-85 FJ600, XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models. Each:
$ 1.95

HCP6643 Aftermarket regulator-rectifier mounting screw FLAT WASHER, 18-8 stainless steel with a bright finish, use 2 per unit. Fits all XJ550, 1984-85 FJ600, XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models. Each:
$ 2.95

HCP25756 Aftermarket regulator-rectifier mounting screw FLAT WASHER, 316 stainless steel, use 2 per unit. Fits all XJ550, 1984-85 FJ600, XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models. Each:
$ 3.95

HCP14285 Aftermarket regulator-rectifier mounting screw FLAT WASHER, black oxide-coated 18-8 stainless steel, use 2 per unit. Fits all XJ550, 1984-85 FJ600, XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models. Each:
$ 2.95

HCP14284 Aftermarket regulator-rectifier mounting screw FLAT WASHER, black oxide-coated hardened alloy steel, use 2 per unit. Fits all XJ550, 1984-85 FJ600, XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models. Each:
$ 2.95



HCP4254 OEM regulator-rectifier mounting FLAT WASHER, use 2 per unit. Fits all XJ900RK, RL, and N/FN models, front side of regulator unit. Each:
$ 2.95


HCP3996 OEM regulator-rectifier mounting NUT, alloy steel with a bright zinc-plated finish. Use 2 per unit. Fits all XJ650 (except Turbo) models, all XJ700 models, and all XJ750 models. Each:
$ 8.95

HCP16570 Aftermarket regulator-rectifier mounting NUT, 18/8 stainless steel with a bright zinc-plated finish. Use 2 per unit. Fits all XJ650 (except Turbo) models, all XJ700 models, and all XJ750 models. Each:
$ 2.95


HCP3047 OEM regulator-rectifier mounting LOCKING NUT, use 2 per unit. Fits all XJ900RK, RL, N/FN, and F models. Each:
$ 8.95

HCP4247 OEM regulator-rectifier mounting NUT PLATE, use 2 per unit. Fits all XJ550 and XJ650 Turbo models. Each:
$ discontinued



HCP2264 OEM bridge plate-to-frame mounting SCREW, panhead phillips-drive alloy steel with a bright zinc-plated finish. Use 1 per bike on all XJ650 Turbo models, each:
$ 7.95

HCP2781N Aftermarket bridge plate-to-frame mounting SCREW, panhead phillips-drive alloy steel with a bright zinc-plated finish. Use 1 per bike on all XJ650 Turbo models, each:
$ 1.95

HCP231N Aftermarket bridge plate-to-frame mounting SCREW, panhead phillips-drive 18-8 stainless steel with a bright finish. Use 1 per bike on all XJ650 Turbo models, each:
$ 2.95

HCP24070 Aftermarket bridge plate-to-frame mounting SCREW, panhead phillips-drive 316 stainless steel with a bright finish. Use 1 per bike on all XJ650 Turbo models, each:
$ 3.95



HCP15738 OEM bridge plate-to-frame mounting SCREW, use 2 per bike on all XJ700 and XJ750-X models. Each:
$ 7.95


HCP315 OEM bridge plate-to-frame mounting screw LOCK WASHER, for use with the HCP2264 screw above. Use 1 on all XJ650 Turbo models.
$ 3.95

HCP916 Aftermarket zinc-plated alloy steel with a natural finish, bridge plate-to-frame mounting screw LOCK WASHER, for use with the HCP2264 screw above. Use 1 on all XJ650 Turbo models.
$ 1.95

HCP319 Aftermarket 18-8 stainless steel bridge plate-to-frame mounting screw LOCK WASHER, for use with the HCP2264 screw above. Use 1 on all XJ650 Turbo models.
$ 2.95

HCP321 Aftermarket black oxide-coated alloy steel bridge plate-to-frame mounting screw LOCK WASHER, for use with the HCP2264 screw above. Use 1 on all XJ650 Turbo models.
$ 1.95



HCP2174 OEM bridge plate-to-frame mounting screw SPECIAL WASHER, use 1 on all XJ650 Turbo models. Each:
$ 2.95

 

SECTION D:

ELECTRICAL SYSTEM:

--Ignition System: Ignition Switch, Keys, Pickup Coil, Ignition Coils, TCI-Igniter, Spark Plugs, Plug Caps, Diodes, and related hardware, etc.



IGNITION SYSTEM PARTS:

IGNITION MAIN SWITCH & KEYS:

is4) OEM and aftermarket IGNITION MAIN SWITCH can be a cause of hard-to-diagnose electrical gremlins. Our brand new OEM and aftermarket replacement switches come complete, ready-to-install, with electrical harness and connector and a matched set of 2 keys. NOTE: replacement keys will not look like the original keys, and the "key position" decal differs slightly in appearance from original.

For info on how to clean your original switch, please review this info:

http://xjbikes.com/forums/index.php?threads/34810

and this:

http://www.xj4ever.com/clean%20and%20lu ... switch.pdf


HCP447 OEM IGNITION MAIN SWITCH, with built-in steering lock mechanism. Fits all XJ550 models, 1984-85 FJ600, 1986-88 FZ600, 1992-93 XJ600 Seca II, all XJ650 models (except Turbo), all 1983 XJ750 Maxim and Midnight Maxim, XJ900RK, and 1978-79 XS1100 models, as well as all of the following models: 1979 RD400F, 1980-82 SR250, 1987 SRX250, 1978-81 XS400, 1980-82 XS400 SG/SH/SJ, 1982-83 XS400 RJ/RK, 1978-83 XS650 Specials, 1980-81 XS650 Standards, 1978-79 XS750 Specials, 1980-81 XS850 Specials, 1983 XV500, 1981-83 XV750, 1983 XV750MK Midnight Specials, 1981-82 XV920 RH/RJ, 1988-99 FZR600, 1987 FZ700, 1985-86 and 1988 FZ750, 1987-88 FZR750R, 1987-93 FZR1000, 1984-85 FJ1100, 1986-87 and 1989-93 FJ1200 models. Comes with two keys.
$ discontinued

HCP1546 Aftermarket IGNITION MAIN SWITCH, with built-in steering lock mechanism. Pretty much an exact reproduction of the original, includes the 3-wire harness with white connector. Fits all XJ550 models, 1984-85 FJ600, 1986-88 FZ600, 1992-93 XJ600 Seca II, all XJ650 models (except Turbo), all 1983 XJ750 Maxim and Midnight Maxim, XJ900RK, and 1978-79 XS1100 models, as well as all of the following models: 1979 RD400F, 1980-82 SR250, 1987 SRX250, 1978-81 XS400, 1980-82 XS400 SG/SH/SJ, 1982-83 XS400 RJ/RK, 1978-83 XS650 Specials, 1980-81 XS650 Standards, 1978-79 XS750 Specials, 1980-81 XS850 Specials, 1983 XV500, 1981-83 XV750, 1983 XV750MK Midnight Specials, 1981-82 XV920 RH/RJ, 1988-99 FZR600, 1987 FZ700, 1985-86 and 1988 FZ750, 1987-88 FZR750R, 1987-93 FZR1000, 1984-85 FJ1100, 1986-87 and 1989-93 FJ1200 models. Comes with two keys. NOTE: the key-position decal that comes with this switch is very close in appearance to original, but not exact. If you want the correct decal, order part HCP7281 from below.
$ 44.95

HCP1252 Aftermarket IGNITION MAIN SWITCH, with built-in steering lock mechanism. Pretty much an exact reproduction of the original, but has the added security feature of using round (rather than flat) keys, thus minimizing the change that anyone will ever pick the lock. Includes the 3-wire harness with white connector. Fits all XJ550 models, 1984-85 FJ600, 1986-88 FZ600, 1992-93 XJ600 Seca II, all XJ650 models (except Turbo), all 1983 XJ750 Maxim and Midnight Maxim, XJ900RK, and 1978-79 XS1100 models, as well as all of the following models: 1979 RD400F, 1980-82 SR250, 1987 SRX250, 1978-81 XS400, 1980-82 XS400 SG/SH/SJ, 1982-83 XS400 RJ/RK, 1978-83 XS650 Specials, 1980-81 XS650 Standards, 1978-79 XS750 Specials, 1980-81 XS850 Specials, 1983 XV500, 1981-83 XV750, 1983 XV750MK Midnight Specials, 1981-82 XV920 RH/RJ, 1988-99 FZR600, 1987 FZ700, 1985-86 and 1988 FZ750, 1987-88 FZR750R, 1987-93 FZR1000, 1984-85 FJ1100, 1986-87 and 1989-93 FJ1200 models. Comes with two keys. NOTE: the key-position decal that comes with this switch is very close in appearance to original, but not exact. If you want the correct decal, order part HCP7281 from below.
$ 44.95


HCP9116 Aftermarket IGNITION MAIN SWITCH, with built-in steering lock mechanism. Pretty much an exact reproduction of the original; however, this version of the switch only includes a single 4-wire harness with the connector. Some original models would have also used a separate 2-wire harness from the switch that would run to the battery fluid level sensor, and this harness is not present on this switch (so you will lose that feature on your dash warning system). Fits all of the following EUROPEAN (non-North American) models only: XJ650 models, all XJ750 models, all XJ900, and all 1980-81 XS1100 models. Comes with two keys.
$ 44.95



HCP18168 OEM rebuilt IGNITION MAIN SWITCH, with built-in steering lock mechanism. Has 2 individual wire harnesses leads with correct color wires and plastic end connectors. Fits all XJ650 Turbo models and XJ750-D models. This unit has a brand new lock cylinder and housing and a rebuilt steering lock mechanism. Comes with two keys. NOTE: a $ 50.00 core charge applies to this item, and a re-usable, same-model, complete main switch must be returned for the core charge to be refunded (key not required). This core charge will be refunded when an original core is returned.
$ 99.95 + $ 50.00 refundable core charge



HCP2914 OEM IGNITION MAIN SWITCH, with built-in steering lock mechanism. Has 2 individual wire harnesses leads with correct color wires and plastic end connectors. Fits 1982 XJ750 Maxim and all 1981-83 XJ750 Seca models. Comes with two keys. Brand new.
$ discontinued

HCP18093 OEM rebuilt IGNITION MAIN SWITCH, with built-in steering lock mechanism. Has 2 individual wire harnesses leads with correct color wires and plastic end connectors. Fits 1982 XJ750 Maxim and all 1981-83 XJ750 Seca models. This unit has a brand new lock cylinder and housing and a rebuilt steering lock mechanism. Comes with two keys. NOTE: a $ 50.00 core charge applies to this item, and a re-usable, same-model, complete main switch must be returned for the core charge to be refunded (key not required). This core charge will be refunded when an original core is returned.
$ 129.95 + $ 50.00 refundable core charge


HCP2916 OEM main IGNITION MAIN SWITCH, with built-in steering lock mechanism. Includes the 3-wire harness with white connector. Fits all 1985-86 XJ700 models, XJ750-X, 1984-87 XV700 Virago, and 1988-97 XV750 Virago models. Comes with two keys. Brand new.
$ 269.95

HCP18169 OEM rebuilt IGNITION MAIN SWITCH, with built-in steering lock mechanism. Has 3-wire harness with white plastic end connector. Fits all 1985-86 XJ700 models, XJ750-X, 1984-87 XV700 Virago, and 1988-97 XV750 Virago models. This unit has a brand new lock cylinder and housing and a rebuilt steering lock mechanism. Comes with two keys. NOTE: a $ 50.00 core charge applies to this item, and a re-usable, same-model, complete main switch must be returned for the core charge to be refunded (key not required). This core charge will be refunded when an original core is returned.
$ 199.95 + $ 50.00 refundable core charge




HCP2171 OEM ignition switch MOUNTING BOLT, 6-point hex head alloy steel fastener with a bright zinc-plated finish, fits all XJ550, 1984-85 FJ600, XJ650, XJ700, XJ750, all XJ900RK, RL, and N models, and all XS1100 models. Use 2 per switch. Each:
$ 3.95

HCP24067 Aftermarket ignition switch MOUNTING BOLT, 6-point hex head alloy steel fastener with a bright zinc-plated finish, fits all XJ550, 1984-85 FJ600, XJ650, XJ700, XJ750, all XJ900RK, RL, and N models, and all XS1100 models. Use 2 per switch. Each:
$ 1.95

HCP24077 Aftermarket ignition switch MOUNTING BOLT, 6-point hex head 18/8 stainless steel fastener with a bright finish, fits all XJ550, 1984-85 FJ600, XJ650, XJ700, XJ750, all XJ900RK, RL, and N models, and all XS1100 models. Use 2 per switch. Each:
$ 2.95

HCP24078 Aftermarket ignition switch MOUNTING BOLT, 6-point hex head 316 stainless steel fastener with a bright finish, fits all XJ550, 1984-85 FJ600, XJ650, XJ700, XJ750, all XJ900RK, RL, and N models, and all XS1100 models. Use 2 per switch. Each:
$ 3.95

HCP6639 Aftermarket ignition switch MOUNTING BOLT, socket head (hex-key drive) 18/8 stainless steel fastener with a bright finish, fits all XJ550, 1984-85 FJ600, XJ650, XJ700, XJ750, all XJ900RK, RL, and N models, and all XS1100 models. Use 2 per switch. Each:
$ 2.95

HCP24075 Aftermarket ignition switch MOUNTING BOLT, socket head (hex-key drive) 18/8 stainless steel fastener with a bright finish, fits all XJ550, 1984-85 FJ600, XJ650, XJ700, XJ750, all XJ900RK, RL, and N models, and all XS1100 models. Use 2 per switch. Each:
$ 2.95

HCP6640 Aftermarket ignition switch MOUNTING BOLT, socket head (hex-key drive) black oxide-coated alloy steel fastener. Fits all XJ550, 1984-85 FJ600, XJ650, XJ700, XJ750, all XJ900RK, RL, and N models, and all XS1100 models. Use 2 per switch. Each:
$ 1.95



HCP13724 OEM ignition switch MOUNTING BOLT, fits all XJ900 FN and F models. Use 2 per switch. Each:
$ 4.95



HCP2173 OEM ignition switch mounting bolt FLAT WASHER, fits all XJ550, FJ600, XJ650, XJ700, XJ750, and all XJ900RK, RL, and N models. Use 2 per switch, original bright finish, each:
$ 2.95

HCP6642 Aftermarket ignition switch mounting bolt FLAT WASHER, zinc-plated alloy steel with a natural finish, fits all XJ550, FJ600, XJ650, XJ700, XJ750, and all XJ900RK, RL, and N models. Use 2 per switch, each:
$ 1.95

HCP6643 Aftermarket ignition switch mounting bolt FLAT WASHER, 18-8 stainless steel with a natural finish, fits all XJ550, FJ600, XJ650, XJ700, XJ750, and all XJ900RK, RL, and N models. Use 2 per switch, each:
$ 2.95

HCP25756 Aftermarket ignition switch mounting bolt FLAT WASHER, 316 stainless steel with a natural finish, fits all XJ550, FJ600, XJ650, XJ700, XJ750, and all XJ900RK, RL, and N models. Use 2 per switch, each:
$ 3.95

HCP14285 Aftermarket ignition switch mounting bolt FLAT WASHER, black oxide-coated 18-8 stainless steel, fits all XJ550, FJ600, XJ650, XJ700, XJ750, and all XJ900RK, RL, and N models. Use 2 per switch, each:
$ 2.95

HCP14284 Aftermarket ignition switch mounting bolt FLAT WASHER, black oxide-coated hardened alloy steel, fits all XJ550, FJ600, XJ650, XJ700, XJ750, and all XJ900RK, RL, and N models. Use 2 per switch, each:
$ 2.95



HCP2181 OEM ignition switch bracket-to-steering crown bracket mounting BOLT, alloy steel with a satin finish (original was bright polished), hex-head bolt. For all XJ1100 models. Use 2 per bike. Each:
$ 2.95

HCP17123 Aftermarket ignition switch bracket-to-steering crown bracket mounting BOLT, 18-8 stainless steel with a bright finish, hex-head bolt. For all XJ1100 models. Use 2 per bike. Each:
$ 2.95

HCP22191 Aftermarket ignition switch bracket-to-steering crown bracket mounting BOLT, 316 stainless steel with a bright finish, hex-head bolt. For all XJ1100 models. Use 2 per bike. Each:
$ 3.95

HCP22189 Aftermarket ignition switch bracket-to-steering crown bracket mounting BOLT, alloy steel with a yellow zinc-plated finish, hex-head bolt. For all XJ1100 models. Use 2 per bike. Each:
$ 1.95

HCP17122 Aftermarket ignition switch bracket-to-steering crown bracket mounting BOLT, alloy steel with a black finish, hex-head bolt. For all XJ1100 models. Use 2 per bike. Each:
$ 1.95



HCP2185 OEM ignition switch bracket-to-steering crown bracket mounting bolt LOCK WASHER, correct bright finish. For all XJ1100 models. Use 2 per bike. Each:
$ 6.95

HCP16209 Aftermarket ignition switch bracket-to-steering crown bracket mounting bolt LOCK WASHER, zinc-plated alloy steel. For all XJ1100 models. Use 2 per bike. Each:
$ 2.95

HCP16100 Aftermarket ignition switch bracket-to-steering crown bracket mounting bolt LOCK WASHER, 18-8 stainless-steel with a bright finish. For all XJ1100 models. Use 2 per bike. Each:
$ 3.95

HCP16102 Aftermarket ignition switch bracket-to-steering crown bracket mounting bolt LOCK WASHER, black-oxide coated alloy steel. For all XJ1100 models. Use 2 per bike. Each:
$ 3.95



HCP17708 Aftermarket main switch lock cylinder wafer COMPRESSION SPRING. These tiny springs fit underneath each lock cylinder wafer and provides the proper tension to enable the wafer to pop "up" and provide the locking function between the cylinder plug and housing. Use one spring per wafer, six per lock cylinder. Each:
$ 1.95

HCP17708SET6 Aftermarket main switch lock cylinder wafer COMPRESSION SPRING, set of 6 springs:
$ 9.95




Ignition Switch ID Decals:

This round switch bezel key-position identification DECAL help to restore that "brand-new" look to refinished original parts.

HCP7281 Aftermarket ignition switch KEY POSITION ID DECAL, round hollow "ring" decal fits on the ignition switch bezel ring and identifies each key position: OFF, ON, LOCK, P (with is for "Park"), and IGNITION wording. Black decal with silvered lettering. Fits all XJ550, FJ600, XJ650, XJ700, XJ750, XJ900, XJ1100 and XS1100 ignition switches. This is a high-quality reproduction of the original.
$ 12.95




KEY BLANKS:

s) Yamaha KEY BLANKS.....please see the long NOTE at the end of this post for additional detail.

All of the following are the correct blank (un-cut) style keys.

The original keys that came with your bike has a small, truly rectangular head that has a black plastic head cap, and the word YAMAHA was cast into this head cap.

The OEM replacement keys that we offer have the YAMAHA wording in the key head, but no black plastic head cap.

Aftermarket keys are available either with or without the black plastic head cap....but do not have the word YAMAHA cast into them.

The aftermarket plastic cap headed keys are very similar in shape to an original Yamaha key from this era, but are slight more trapezoidal than original (as opposed to being a true rectangle).

The aftermarket metal-headed keys are approximately the same size and shape as original plastic-capped keys. Unlike the replacement keys that most lock shops have available for older Yamaha locks (which will work just fine, but usually have a huge, rather ugly head), our keys have the small rectangular head that is similar in size to original.


NOTE: although we offer the following key BLANKS, we do not offer any pre-cut keys, since we have no way of translating your key code---should you even know it!---into a fully cut key. Nor do we have any method of translating your bike's VIN into the original key-code (some older Yamaha dealers MAY have this information, but don't count on it).

As long as you have a key that fits your lock(s), anyone with a key-cutting machine will be able to copy your key pattern onto any of the following key blanks. Additionally, if you have a professional locksmith in your area.....and one that has been in business for a LONG time (and thus has the older conversion books available), then they may be able to convert your key code and cut a key without having a master key to copy from.


P.S. If you lose your key(s), or obtain a used gas tank that still has a (locked) cap on it but with no key, then it may be time for you to learn the ancient art of lock-picking:

http://www.capricorn.org/~akira/home/lockpick/


All keys have to be ordered according to their Key Blank Style (A-F).

NOTE ON KEY BLANK STYLES: Yamaha used 6 different key blank styles, designated as A, B, C, D, E, or F, and you can re-key an individual lock only to another pattern within the same key blank style.

Originally, your bike came with two keys that were cut to the same pattern and fit ALL of the locks on your bike (ignition switch, gas cap, seat and/or helmet lock, Powerlock chain if so equipped, etc.). These keys were unique to your bike, and were cut to a specific pattern which was identified by a KEY CODE. This key code was stamped onto the key head, and also was either stamped into the base (bottom) of the ignition switch housing, or has a small metallic adhesive-backed tag that had the key code stamped into it and that was affixed to the bottom of the ignition lock housing. THERE IS NO OTHER PLACE ON YOUR BIKE WHERE THIS KEY CODE APPEARS!. None of the other locks on your bike have the key code impressed, stamped, or labeled upon them.

In the old days, you could have Yamaha cut a new key for you by presenting your bike's VIN number to them, as they had VIN-to-Key Code translation information available to them. Few, if any, dealers still have such information still available for these older bikes.


Key Blank Style Determination:

Of course, if you have the original key that came with your bike, then the entire key code (letter and 5 numbers) is stamped onto the key head, right below the black plastic cap.

If not, you can determine what key blank style you have by removing your ignition switch.......and the entire key code is either stamped into the bottom of the switch housing, or is printed or etched onto a paper or aluminum tag that is glued to the bottom of the ignition lock. The key number always starts with one of the letters A-F, followed by 5 or 6 numbers. The 5 or 6 numbers are actually the "serial number" of the individual lock. You can see what this code appears like here:

www.xjbikes.com/forums/threads/no-key-questions-and-other-missing-parts.130762

Note that some switches will have this code on a foil sticker, rather than stamped into the switch body (as shown above).


Swapping Lock Mechanisms:

The lock mechanism can always be removed from an individual component (ignition switch, gas cap, or seat/helmet lock unit) and swapped out from another similar unit. For example, if your bike originally uses locks that accept a "D" style key blank, then you can substitute another "D" style lock mechanism from a donor bike and then have that donor lock re-keyed to match all of your other original locks on your bike.....usually an expensive task at a real locksmith, but it can be done (or you can do it at home, if you have the patience of Job). However, if your bike originally uses locks with a "C" style key blank, and you buy a gas cap with a lock and that gas cap lock uses a "F" style key, you cannot have that "F" style lock mechanism re-keyed to accept the "C" style key.


Hope that isn't too much info.....but when buying replacement parts that incorporate a lock mechanism, it's useful to keep the above in mind in case you want to have all your locks keyed the same.


Finally, remember that except for the ignition switch, the key blank style and key code (A-F) is NOT stamped nor engraved or marked on any other lock mechanism. The only way to determine which key style (for example) another gas cap lock uses is to try a key into it (even a blank, un-cut key); an "A" style key won't fit into a B-F style lock, etc. (although we have found that "C" and "E" blanks will sometimes interchange......). If you're buying a used ignition switch, with or without the key, you'll have a good chance of knowing which key style it uses as there is a key code printed or engraved on the bottom of the switch housing (assuming the printed or engraved label has not gone bye-bye after all these years); all other locks (gas, helmet/seat, and powerlock) you must either have the original key or know the ignition switch key number of the bike that component came from.


Key Blanks:

HCP9186 OEM "A" style KEY BLANK with metal head, no cap
$ 18.95

HCP188 Aftermarket "A" style KEY BLANK with black plastic cap.
$ 12.95

HCP194 Aftermarket "A" style KEY BLANK with metal head; no cap
$ 9.95



HCP9187 OEM "B" style KEY BLANK with metal head, no cap
$ 18.95

HCP189 Aftermarket "B" style KEY BLANK with black plastic cap.
$ 12.95

HCP195 Aftermarket "B" style KEY BLANK with metal head; no cap
$ 9.95



HCP9188 OEM "C" style KEY BLANK with metal head, no cap.
$ 29.95

HCP190 Aftermarket "C" style KEY BLANK with black plastic cap
$ 17.95

HCP196 Aftermarket "C" style KEY BLANK with metal head; no cap
$ 9.95



HCP9189 OEM "D" style KEY BLANK with metal head, no cap.
$ 29.95

HCP191 Aftermarket "D" style KEY BLANK with black plastic cap.
$ 17.95

HCP197 Aftermarket "D" style KEY BLANK with metal head; no cap.
$ 9.95



HCP9190 OEM "E" style KEY BLANK with metal head, no cap.
$ 12.95

HCP192 Aftermarket "E" style KEY BLANK with black plastic cap.
$ 10.95

HCP198 Aftermarket "E" style KEY BLANK with metal head; no cap.
$ 9.95



HCP9191 OEM "F" style KEY BLANK with metal head, no cap.
$ 18.95

HCP193 Aftermarket "F" style KEY BLANK with black plastic cap.
$ 12.95

HCP199 Aftermarket "F" style KEY BLANK with metal head; no cap.
$ 9.95



HCP17031 Aftermarket replacement KEY used on the small locks fitted originally to all Yamaha models with factory saddlebags or trunk systems using the original Presto Lock Company locks. Already "cut", as these locks were standardized (universal) and did not use special coded keys. Each:
$ 9.95



NOTE: the following product(s) can only be shipped via ground transport (which thus eliminates the postal Priority Mail, postal Express Mail, or private carrier Expedited levels of service for this item) and cannot (and will not----don't even ask!) be shipped outside of the continental USA. Additionally, there may be a per-package weight or quantity restriction, and thus multiple-unit orders of this product may have to be shipped in separate packages and will incur additional shipping charges.

HCP20863 Aftermarket super-duty GRAPHITE LUBE, in a generous 10-ounce aerosol can. The 800-pound gorilla of lubricants, it's infused with pure graphite, goes on wet, and then dries in 10 minutes to a super-slick, high-pressure, bearing-like finish which provides the ultimate level of protection. Prevents rust, won't wash off, throw off, and won't attract dust or dirt. Surfaces must be clean and dry of previous oils, etc. before application. Can be used as an engine assembly lube, bearing or bushing pre-lube, great for lock cylinders, and all metallic sliding surfaces. Use where dusty or dirty conditions render oil-based lubricants ineffective or undesirable.
$ 42.95





IGNITION SYSTEM OVERVIEW:

Before we get into the list of components within your ignition system, it may be useful to explore the basics of the ignition design used on these bikes, as this knowledge may help you to better recognize, troubleshoot, and repair performance problems with your engine that you think may be due to these components.

The ignition system actually begins at the left end of your CRANKSHAFT, since the rotational position of the crankshaft determines the position of the pistons and of the camshafts. Obviously, since the purpose of the entire ignition system is to deliver a high-voltage spark at the plugs at exactly the proper instant----meaning, as the piston approaches Top Dead Center of the compression stroke----then the ignition system must "know" what the position of the crankshaft is in order to transfer that information (via electrical signals) to the major components: the PICK-UP COILS, then onto the TCI UNIT, to the IGNITION COILS, via the PLUG WIRES and through the PLUG CAPS and finally, onto the SPARK PLUGS.

But it all begins at the crankshaft, which has a flat metal ROTOR DISC bolted onto the left side snout, and which hides under the left side, round "Oil Pump Cover" (also called a "YICS" cover on YICS-equipped engines). This spinning rotor disc has a small magnet embedded within it's outer tip, and as that outer tip rotates past the fixed magnets within the PICK-UP COILS, the interaction of magnetic fields triggers a small voltage in the pick-up coil wires that lead to the TCI UNIT.

Note that since the rotor disc is fixed in position and spins along with the crankshaft, this rotor disc "knows" the position of the crankshaft at all times. And since the pick-up coils are bolted in place, and are thus stationary, whenever the spinning rotor passes by a fixed pick-up coil, and thus triggers it to send a voltage signal to the TCI, in this way the TCI unit thus also "knows" where the crankshaft is, rotationally-speaking, and thus where the pistons are in relation to Top Dead Center and when their spark plugs need to be fired.......

Also note that since there are only two pick-up coils for your four-cylinder engine, that each pick-up coil is actually providing the "firing signal" to the TCI unit for two different cylinders. In these engines, one pick-up coil is responsible for sending the signal to the TCI that eventually leads to the spark plugs firing off for cylinders #1 and #4 at the same time, and the other pick-up coil sends the message to the TCI unit to fire off spark plugs #2 and #3, again, at the same time.

Although this may seem odd at first, the mechanical arrangement within the engine of the crank throws, and thus the rods and pistons, as well as the camshaft timing, allow this situation to proceed without a problem; in fact, when one of these "paired" cylinders (for example, #1) is approaching Top Dead Center of it compression stroke----and thus is in need of a spark from its spark plug----it's "mated" cylinder (#4) is also approaching Top Dead Center, too.........but on its exhaust stroke.......and so even though cylinder #4 gets a spark at its spark plug, there's nothing in the cylinder to combust, and thus it's a "wasted" (yet harmless) spark that occurs in cylinder #4.

Obviously, the exact same situation occurs in the mated pair of cylinders #2 and #3.

In fact, the whole system is known as the "wasted spark" system, since one of the two sparks that always occur at the same time is "wasted" on a cylinder that is on its exhaust stroke............


Anyway, to continue our journey: when a pick-up coil is energized by the passing magnetic field of the spinning rotor disc, it send an electrical impulse signal to the TCI. Therefore, the TCI unit now also "knows" the position of the crankshaft (and thus of the piston). Using other sensor information.....primarily, the rotational speed (RPM's) of the engine......the computer chip in the TCI is then responsible for calculating exactly when to send a "message" to the proper IGNITION COIL to release it's energy to the proper cylinders. And note that we said "cylinders" (plural), since just like the pick-up coils, one ignition coil also sparks two cylinders at once (part of the same "wasted spark" method discussed above).


The ignition coils use a rather small (12V) input on their primary side to product a large (20,000V +) amount of electrical energy on their discharge (spark plug wires). When the TCI unit determines that "the time is right" for a particular coil to fire, it grounds that coil, which collapses the small magnetic field inside the primary side of the coil, which thus induces a large electrical field in the secondary (plug wires) side of the coil, which then rushes to ground. This electrical energy rushes down the non-resistive PLUG WIRES, through a resistor in the SPARK PLUG CAP, and finally jumps a small gap in the spark plug electrode on it's way to ground, and thus the spark occurs that fires the air-fuel mixture (in one of the two cylinders being sparked at the same time), things go boom, power gets produced, and you're on the way down the road........

A great explanation and diagram---starting at the 4:15 mark in the video---explains all of the above in a very simplified, yet understandable detail:




By the way, the firing order for the XJ550 thru XJ900 engines is 1-2-4-3, with the two center pistons coming up while the two outer pistons are going down, and the direction of engine rotation is in the same direction as your tires rotate when moving forward.



Now, What Could Go Wrong?:

Well, remember, all of these components are basically used to transmit knowledge of where the piston is within its four-stroke cycle, and to be able to deliver a spark at the appropriate time to each cylinder to take advantage of the compressed air-fuel mixture in the cylinder (during the compression stroke). So it sometimes help to understand these component pieces as being mainly responsible for providing this stream of precise information, and the electrical-spark making (at the spark plug gap) as merely being the natural (according to the laws of physics and electricity) end-result of all this information handling and processing.


Now, unless your crankshaft was installed backwards (an impossibility, by the way!) or the camshaft was installed improperly (or if the camshaft drive chain has skipped a tooth----not a common occurrence, at all), then we can safely ignore all of these issues. And since the spinning rotor disc used to trigger the pick-up coils is bolted firmly in place at the end of the crankshaft, it can be ignored for troubleshooting issues.


But the pick-up coils themselves can go bad over time, and even though it's rare, it can happen. No pick-up coil signal out----along their wires to the TCI unit-----means no signal into the TCI unit, and the whole system breaks down. Which means the small wires from the pick-up coils to the TCI had better not be pinched, shorted to ground, or broken internally, or the message just won't get through.

NOTE: if you are having intermittent or difficult-to-diagnose ignition system problems, it may be that the wire leads from the pick-up coils (under the left round crank-end cover) have become pinched where they exit the cover and have worn through their insulation.


Of course, if the TCI unit itself is defective, then even if it is getting a signal from the pick-up coils, it is unable or unwilling to process the signal, or the signal gets processed incorrectly, and either the signal doesn't get sent to the ignition coils at the proper time, or doesn't get sent at all.


But even if the pick-up coils and the TCI are performing flawlessly---which they usually are----if the ignition coils are not getting enough voltage input to them, or, if they are not able to multiply the small incoming voltage into a much higher output voltage (that is, after all, their main purpose in life), then we have a problem.

Worn-out ignition coils, or coils that perform poorly or get cracks in their outer cases (and thus short out when moisture enters their internal shells), are a common cause of ignition system problems.


And even if the coils are performing properly, if the spark plug wires have an internal break, or an external break, and thus prevent the coil electrical output from reaching the plugs, then nothing good is going to come from all this activity.


Of course, the spark plug Resistor Caps also play a role. They have a tiny resistor embedded within them, and the purpose of the resistor is to provide, of course, electrical resistance to the flow of electrical energy. There are a couple of reasons why some resistance is necessary-----it helps eliminate electrically-generated Radio Frequency Interference "noise" (RFI), it provides a "cushion" against instantaneous electrical energy pulses (which is really hard on small, fragile electrical components, such as the capacitors and transistors in the TCI unit), and it "slows down" the passage of the electricity through the spark plug, thus providing a sort of "electrical Viagra" to spark at the plugs, allowing the electrical discharge (and thus the spark) to last a bit longer (instead of being instantaneous), thus promoting more-better and fuller combustion of the air-fuel mixture.

In fact, outside of the RFI suppression issues, it is the control of this "spark burn time" that is really the most critical issue, especially on bikes that are jetted a bit lean to begin with........as increased electrical resistance in the secondary circuit will increase the spark firing or "burn" time, and that longer burning spark assists in the more complete combustion of harder-to-fire lean fuel mixtures.


But those resistors in the spark plug caps........or in the spark plugs themselves, for those engines that use resistor plugs........do wear out over time. And when they do, their resistance increases, which means that they provide more resistance to the flow of electricity than is needed. So that 20,000 volts of electrical energy, instead of being discharged at the spark plug gap in a rather short (10 milliseconds) amount of time, gets "spread out" over a much longer period of time, and gets reduced in voltage, too. So when plug caps or plugs "go bad", they rarely fail to the point where no spark occurs at all, it's just that the electrical output is being "spread out" over such a long period of time that the energy being created in the spark plug gap is so low that it's not enough to fire the fuel mixture completely (or at all)........and that's what leads to hard starts and poor performance (and reduced gas mileage, too).

By the way, as you may have figured out by now, a spark plug that is contaminated ("fouled") by carbon or oil deposits, or one which has too large of a gap, fail to operate properly mainly because such situation can greatly increase the electrical resistance characteristics of such a plug.........and now you know why that's not a good thing.

NOTE: some models specify a different (higher) plug cap resistance for the inner 2 cylinders vs. the outer cylinders. The probable reason for this is that the inner pair of cylinders may run a bit leaner (at least on some engines) since they run warmer, and also because the YICS system should allow the inner pair to “steal” more than the outer pair. If they’re really effectively leaner, they'll need a longer duration of a spark to ignite their charge, and of course the way to achieve that is: you guessed it, increased resistance on those inner cylinders!


A very good review of the issue of electrical resistance in ignition systems can be found at:

http://www.motorcycleproject.com/motorcycle/text/plugwiretech.html

and

http://www.ultralightnews.com/enginetroublshooting/resistorcapsandplugs.htm

Although the above article references the ignition systems in ultra-light aircraft, the same concepts apply to all ignition systems.


Okay, so that's your nickel tour, and although it's not as detailed as it could be, hopefully it's enough to get you started. A good voltmeter (also called an ohmmeter) is an invaluable friend when trying to track down ignition system problems, as you must make sure that the "information" between components is actually able to travel from Point A to Point B properly, and that the individual components are, electrically-speaking, able to process and transmit the electrical information properly.



SO, WHY WON’T IT START?

Well, in order for your engine to start and run, you’ve got to have fuel, spark, and enough engine compression.

The following article is THE authoritative testing procedure if you suspect a no-start situation is due to ignition system issue. Obviously, it assumes that:

a) you are getting fuel into the carbs (verify this by loosening one (or all of them, but one at a time!) of the carb bowl drain screws and see if some fuel leaks out. If so, you got fuel! If not, you’ll need to tackle this issue and figure out why.

b) you have good engine compression. If you’re not sure, you’ll need to perform a compression test and verify that then engine is making enough compression.

c) your battery should be fully charged:

While the starter is engaged (but before the bike starts), the battery voltage should be 9.5 volts or greater. If not, then this signals either a bad battery, very dirty or weak electrical connections, or it could be an incredibly problematic starter motor (not likely; it's probably the battery!).

A low voltage during cranking will prevent the ignition coils from getting enough voltage to charge themselves enough to deliver a good spark to the plugs.

http://www.xjbikes.com/forums/threads/how-to-ignition-troubleshooting.21932/




Ignition system firing order:

It's 1-2-4-3 for all engines.



Ignition system components resistance specifications:

The following list also covers the resistance values of the spark plugs, plug caps, the ignition pick-up coils (which are located behind the left side round crankshaft end cover)m and the ignition coils. The resistance of the pick-up coils can be checked at their connector to the TCI box by measuring the resistance between the grey and the black wire (this checks the condition of the first pick-up coil) and then between the orange and the black wire (this is the resistance of the other pick-up coil).

NOTE: "K" is abbreviation for a thousand units, so "5K" ohms = 5,000 ohms of resistance, etc.

NOTE: some models within this era could have been fitted with "noise suppression" plug caps (these caps are evidenced by a metal "shield" wrapped around the plastic cap body) and such caps may have used a higher resistance rating as opposed to their stock ratings listed below (for non "noise suppression" style caps).


XJ550 models:

Pick-up coils:
650 ohms +/- 20% = 520 ohms to 780 ohms acceptable range


Ignition Coils:

Primary side (input from main wiring harness):
2.5 ohms +/- 10% = 2.25 ohms - 2.75 ohms acceptable range

Secondary side (spark plug wires, without their end caps):
11K ohms +/- 20% = 8,800 ohms - 13,200 ohms acceptable range


Spark plug caps:
10K +/- 20% = 8,000 to 12,000 ohms per cap acceptable range

Spark plugs:
0 ohms per plug




XJ650 models:

Pick-up coils:
1980-81 XJ650 Maxim and Midnight Maxim: 700 ohms +/- 20% = 560 ohms to 840 ohms acceptable range
1982 XJ650RJ Seca (non-yics engines): 700 ohms +/- 20% = 560 ohms to 840 ohms acceptable range
1982-84 XJ650 Maxim: 650 ohms +/- 20% = 520 ohms to 780 ohms acceptable range
1982 XJ650RJC Seca (yics engine): 650 ohms +/- 20% = 520 ohms to 780 ohms acceptable range
1982-83 XJ650 Turbo: 120 ohms +/- 20% = 96 ohms to 144 ohms acceptable range


Ignition Coils:

Primary side (input from main wiring harness):
2.5 ohms +/- 10% = 2.25 ohms - 2.75 ohms acceptable range

Secondary side (spark plug wires, without their end caps):
11K ohms +/- 20% = 8,800 ohms - 13,200 ohms acceptable range


Spark plug caps:
5K +/- 20% = 4,000 to 6,000 ohms per cap acceptable range

Spark plugs:
0 ohms per plug




XJ700 air-cooled models:

Pick-up coils:
120 ohms +/- 20% = 96 ohms to 144 ohms acceptable range


Ignition Coils:

Primary side (input from main wiring harness):
2.7 ohms +/- 10% = 2.43 ohms - 2.97 ohms acceptable range

Secondary side (spark plug wires, without their end caps):
12K ohms +/- 20% = 9,600 ohms - 14,400 ohms acceptable range


Spark plug caps:
1985 N/NC models: 5K +/- 20% = 4,000 to 6,000 ohms per cap acceptable range
1986 S/SC models: 10K +/- 20% = 8,000 to 12,000 ohms per cap acceptable range


Spark plugs:
1985 N/NC models: 0 ohms per plug
1986 S/SC models: 5K ohms per plug




XJ700-X water-cooled models:

Pick-up coils:
120 ohms +/- 20% = 96 ohms to 144 ohms acceptable range


Ignition Coils:

Primary side (input from main wiring harness):
2.7 ohms +/- 10% = 2.43 ohms - 2.97 ohms acceptable range

Secondary side (spark plug wires, without their end caps):
12K ohms +/- 20% = 9,600 ohms - 14,400 ohms acceptable range


Spark plug caps:
10K +/- 20% = 8,000 to 12,000 ohms per cap acceptable range


Spark plugs:
1985 XN/XNC models: 0 ohms per plug
1986 SX/SXC models: 5K ohms per plug




XJ750 air-cooled models:

Pick-up coils:
650 ohms +/- 20% = 520 ohms to 780 ohms acceptable range


Ignition Coils:

Primary side (input from main wiring harness):
2.5 ohms +/- 10% = 2.25 ohms - 2.75 ohms acceptable range

Secondary side (spark plug wires, without their end caps):
11K ohms +/- 20% = 8,800 ohms - 13,200 ohms acceptable range


Spark plug caps:
1981-83 models: 5K +/- 20% = 4,000 to 6,000 ohms per cap acceptable range
1984 RL models: 10K +/- 20% = 8,000 to 12,000 ohms per cap acceptable range

Spark plugs:
0 ohms per plug




XJ750-X water-cooled models:

Pick-up coils:
120 ohms +/- 20% = 96 ohms to 144 ohms acceptable range


Ignition Coils:

Primary side (input from main wiring harness):
2.7 ohms +/- 10% = 2.43 ohms - 2.97 ohms acceptable range

Secondary side (spark plug wires, without their end caps):
12K ohms +/- 20% = 9,600 ohms - 14,400 ohms acceptable range


Spark plug caps:
10K +/- 20% = 8,000 to 12,000 ohms per cap acceptable range

Spark plugs:
5K ohms per plug




XJ900RK, RL, N, FN, and F models:

Pick-up coils:
120 ohms +/- 20% = 96 ohms to 144 ohms acceptable range


Ignition Coils:

Primary side (input from main wiring harness):
original coils, marked CM12-20: 2.7 ohms +/- 10% = 2.43 ohms - 2.97 ohms acceptable range
replacement coils, marked CM12-09 or CM12-10: 2.5 ohms +/- 10% = 2.25 ohms - 2.75 ohms acceptable range

Secondary side (spark plug wires, without their end caps):
original coils, marked CM12-20: 13.2K ohms +/- 20% = = 10,560 ohms - 15,840 ohms acceptable range
replacement coils, marked CM12-09 or CM12-10: 11K ohms +/- 20% = 8,800 ohms - 13,200 ohms acceptable range


Spark plug caps:
RK and RL models: 5K +/- 20% = 4,000 to 6,000 ohms per cap acceptable range
N, FN, and F models: 10K +/- 20% = 8,000 to 12,000 ohms per cap acceptable range
S and SH models: 15K +/- 20% = 12,000 to 18,000 ohms per cap acceptable range

Spark plugs:
RK and RL models: 0 ohms per plug
N, FN, and F models: 5K ohms per plug




XJ1100 models:

Pick-up coils:
120 ohms +/- 20% = 96 ohms to 144 ohms acceptable range


Ignition Coils:

Primary side (input from main wiring harness):
2.5 ohms +/- 10% = 2.25 ohms - 2.75 ohms acceptable range

Secondary side (spark plug wires, without their end caps):
11K ohms +/- 20% = 8,800 ohms - 13,200 ohms acceptable range


Spark plug caps:
5K +/- 20% = 4,000 to 6,000 ohms per cap acceptable range

Spark plugs:
0 ohms per plug




XS1100 models:

Pick-up coils:
720 ohms +/- 20% = 576 ohms to 864 ohms acceptable range


Ignition Coils:

Primary side (input from main wiring harness):
1.5 ohms +/- 10% = 1.35 ohms -1.65 ohms acceptable range

Secondary side (spark plug wires, without their end caps):
15K ohms +/- 20% = 12,000 ohms - 18,000 ohms acceptable range


Spark plug caps:
5K +/- 20% = 4,000 to 6,000 ohms per cap acceptable range

Spark plugs:
0 ohms per plug




IGNITION PICK-UP COILS:

One of the nice things about the stock XJ electrical systems is the transistorized (maintenance free) ignition systems.......no points to set or timing to adjust (except on 1986 XJ700-X models). All of those dreadful chores are handled for you, automatically, via the IGNITION PICK-UP COILS SYSTEM, and further down the line, via the TCI CONTROL MODULE. These components are generally very reliable, almost to the point of being bulletproof, and as mentioned, are truly "plug-and-play" devices that need no periodic maintenance once installed. However, they are quite susceptible to damage via electrical shorts or voltage surges (i.e. if you jumper the battery incorrectly, etc.).


Checking pick-up coils:

The resistance across each pair of lead wires (at the TCI) should be checked as shown in the following video……note that resistance valves specified in the service manual is for measurements taken at 70-F, and as the coils heat up, their resistance values will change, and the use of a hair dryer or heat gun to warm up the coils is simple way to see if values go way out of range as the coils heat up:




Resistance values at 70-F are as follows:

120 ohms +/- 10% for all XJ650 Turbo models, XJ700 all models and XJ750-X models, XJ900RK, RL, N/FN, and F models, and XJ1100 models.

650 ohms +/- 20% for all XJ550 models, 1982-84 XJ650 Maxim, 1982 XJ650RJC Seca (Canadian, yics-engine), and all air-cooled XJ750 models.

700 ohms +/- 20% for all 1980-81 XJ650 models and 1982 XJ650RJ (non-yics engine) models.

720 ohms +/- 20% for all XS1100 models

NOTE: if measuring the resistance when the pick-up coils are hot (i.e. after the engine has been running for 20 minutes or more, such that the pick-up coils are fully heat-saturated), then the resistance readings will be higher by 100 – 150 ohms than at the 70-F “cold” readings shown above.

NOTE: if both coils are out of specifications, suspect a pinched or shorted black ground wire, which is a shared ground for both of the pick-up coils on most models. It is very unlikely (although not impossible, especially in a case of improper jump-starting, etc.) that BOTH pick-up coils would expire at the same time!


A simple test to see if the coils are working, at all is to place a voltmeter (preferably an analog unit) across the Grey or the Orange wire to the Black wire. Energize the system and watch for voltage pulses as you rotate the reluctor past the pickup. This can be done by hand or with the starter.......we'd recommend using the hand method so that the pulses are slow enough to see. These "pulses" are what the TCI "black box" counts and interprets when "deciding" when to fire the ignition coils.


NOTE: the orange lead wire is the trigger wire for the #1/#4 ignition coils, while the grey lead wire is the trigger for the #2/#3 ignition coils.


Pick-Up Coils Baseplate and Lead Wire Harness:

NOTE: whenever you remove or replace your pick-up coils Baseplate unit, it will be necessary to check and perhaps adjust the engine timing. See your factory service or workshop manual for the proper procedure to check and/or adjust your ignition timing!

NOTE: the screws that hold the unit to the engine case are lock-tighted in place, and we strongly suggest that you use a proper-szie (#2) JIS screwdriver to remove them!


HCP503 OEM pick-up coils COILS AND BASEPLATE UNIT, for all XJ700, XJ750-X, and XJ900RK, RL, N/FN, and F models.
$ discontinued



HCP15736 Aftermarket pick-up coils-to-baseplate MOUNTING SCREW, with integral lockwasher. For all XJ550, XJ650, XJ700, XJ750, XJ900RK, RL, and N/FN models, and XJ1100 models, use 2 per coil. NOTE: these screws should be installed with a low-strength thread locking fluid on their threads. Each:
$ 1.95



HCP4189 OEM pick-up coils pick-up coils baseplate LOCATING DOWEL PIN, for all XJ550, FJ600, XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models, use 1 per engine.
$ 7.95


HCP314 OEM pick-up coils baseplate MOUNTING SCREW, for all XJ550, 1984 FJ600 models, XJ650, XJ750, XJ900RK, RL, and N/FN models, and XJ1100 models, use 2 per base. Zinc-plated alloy steel, panhead, phillips-drive. NOTE: these screws should be installed with a low-strength thread locking fluid on their threads. Each:
$ 3.95

HCP5335 OEM pick-up coils baseplate MOUNTING SCREW, for all XJ550, 1984 FJ600 models, XJ650, XJ750, XJ900RK, RL, and N/FN models, and XJ1100 models, use 2 per base. Black alloy steel, panhead, phillips-drive. NOTE: these screws should be installed with a low-strength thread locking fluid on their threads. Each:
$ 8.95

HCP915 Aftermarket pick-up coils baseplate MOUNTING SCREW, for all XJ550, 1984 FJ600 models, XJ650, XJ750, XJ900RK, RL, and N/FN models, and XJ1100 models, use 2 per base. Zinc-plated alloy steel, panhead, phillips-drive. NOTE: these screws should be installed with a low-strength thread locking fluid on their threads. Each:
$ 1.95

HCP316 Aftermarket pick-up coils baseplate MOUNTING SCREW, for all XJ550, 1984 FJ600 models, XJ650, XJ750, XJ900RK, RL, and N/FN models, and XJ1100 models, use 2 per base. 18-8 stainless steel, panhead, phillips-drive. NOTE: these screws should be installed with a low-strength thread locking fluid on their threads. Each:
$ 2.95

HCP317 Aftermarket pick-up coils baseplate MOUNTING SCREW, for all XJ550, 1984 FJ600 models, XJ650, XJ750, XJ900RK, RL, and N/FN models, and XJ1100 models, use 2 per base. 18-8 stainless steel with a polished button head, hex-drive. NOTE: these screws should be installed with a low-strength thread locking fluid on their threads. Each:
$ 2.95

HCP318 Aftermarket pick-up coils baseplate MOUNTING SCREW, for all XJ550, 1984 FJ600 models, XJ650, XJ750, XJ900RK, RL, and N/FN models, and XJ1100 models, use 2 per base. 18-8 stainless steel with a smooth, polished socket head, hex-drive. NOTE: these screws should be installed with a low-strength thread locking fluid on their threads. Each:
$ 2.95

HCP320 Aftermarket pick-up coils baseplate MOUNTING SCREW, for all XJ550, 1984 FJ600 models, XJ650, XJ750, XJ900RK, RL, and N/FN models, and XJ1100 models, use 2 per base. Black-oxide coated alloy steel with a ribbed socket head. NOTE: these screws should be installed with a low-strength thread locking fluid on their threads. Each:
$ 1.95



HCP4184 OEM pick-up coils baseplate MOUNTING SCREW, for all 1985 FJ600 models, XJ700, XJ750-X, and XJ900 N/FN models, use 2 per base. NOTE: these bolts should be installed with a low-strength thread locking fluid on their threads. Each:
$ 2.25



HCP3575 OEM pick-up coils baseplate FLAT WASHER, for all 1981-82 XJ550, 1980-82 XJ650 (except Turbo), 1981-82 XJ750 Seca, and 1982 XJ750 Maxim models, use 2 per base. Each:
$ 6.95

HCP2173 OEM pick-up coils baseplate FLAT WASHER, for all 1983 XJ550, 1985 FJ600 models, 1983-4 XJ650 Maxim and all XJ650 Turbo, 1983 XJ750 Seca, 1983 XJ750 Maxim and Midnight Maxim models, and XJ900RK, RL, N/FN, and F models, use 2 per base, original bright finish, each:
$ 2.95

HCP6642 Aftermarket pick-up coils baseplate FLAT WASHER, zinc-plated alloy steel with a bright finish, for all 1983 XJ550, 1985 FJ600 models, 1983-4 XJ650 Maxim and all XJ650 Turbo, 1983 XJ750 Seca, 1983 XJ750 Maxim and Midnight Maxim models, and XJ900RK, RL, N/FN, and F models, use 2 per base, each:
$ 1.95

HCP6643 Aftermarket pick-up coils baseplate FLAT WASHER, 18-8 stainless steel with a bright finish, for all 1983 XJ550, 1985 FJ600 models, 1983-4 XJ650 Maxim and all XJ650 Turbo, 1983 XJ750 Seca, 1983 XJ750 Maxim and Midnight Maxim models, and XJ900RK, RL, N/FN, and F models, use 2 per base, each:
$ 2.95

HCP25756 Aftermarket pick-up coils baseplate FLAT WASHER, 316 stainless steel with a dull finish, for all 1983 XJ550, 1985 FJ600 models, 1983-4 XJ650 Maxim and all XJ650 Turbo, 1983 XJ750 Seca, 1983 XJ750 Maxim and Midnight Maxim models, and XJ900RK, RL, N/FN, and F models, use 2 per base, each:
$ 3.95

HCP14285 Aftermarket pick-up coils baseplate FLAT WASHER, black oxide-coated 18-8 stainless steel, for all 1983 XJ550, 1985 FJ600 models, 1983-4 XJ650 Maxim and all XJ650 Turbo, 1983 XJ750 Seca, 1983 XJ750 Maxim and Midnight Maxim models, and XJ900RK, RL, N/FN, and F models, use 2 per base, each:
$ 2.95

HCP14284 Aftermarket pick-up coils baseplate FLAT WASHER, black oxide-coated hardened alloy steel, for all 1983 XJ550, 1985 FJ600 models, 1983-4 XJ650 Maxim and all XJ650 Turbo, 1983 XJ750 Seca, 1983 XJ750 Maxim and Midnight Maxim models, and XJ900RK, RL, N/FN, and F models, use 2 per base, each:
$ 2.95




HCP2173 OEM pick-up coils baseplate FLAT WASHER, for all 1983 XJ550, 1985 FJ600 models, 1983-4 XJ650 Maxim and all XJ650 Turbo, 1983 XJ750 Seca, 1983 XJ750 Maxim and Midnight Maxim models, and XJ900RK, RL, N/FN, and F models, use 2 per base, original bright finish, each:
$ 2.95

HCP6642 Aftermarket pick-up coils baseplate FLAT WASHER, zinc-plated alloy steel with a natural finish, for all 1983 XJ550, 1985 FJ600 models, 1983-4 XJ650 Maxim and all XJ650 Turbo, 1983 XJ750 Seca, 1983 XJ750 Maxim and Midnight Maxim models, and XJ900RK, RL, N/FN, and F models, use 2 per base, each:
$ 1.95

HCP6643 Aftermarket pick-up coils baseplate FLAT WASHER, 18-8 stainless steel with a natural finish, for all 1983 XJ550, 1985 FJ600 models, 1983-4 XJ650 Maxim and all XJ650 Turbo, 1983 XJ750 Seca, 1983 XJ750 Maxim and Midnight Maxim models, and XJ900RK, RL, N/FN, and F models, use 2 per base, each:
$ 2.95

HCP25756 Aftermarket pick-up coils baseplate FLAT WASHER, 316 stainless steel with a natural finish, for all 1983 XJ550, 1985 FJ600 models, 1983-4 XJ650 Maxim and all XJ650 Turbo, 1983 XJ750 Seca, 1983 XJ750 Maxim and Midnight Maxim models, and XJ900RK, RL, N/FN, and F models, use 2 per base, each:
$ 3.95

HCP14285 Aftermarket pick-up coils baseplate FLAT WASHER, black oxide-coated 18-8 stainless steel, for all 1983 XJ550, 1985 FJ600 models, 1983-4 XJ650 Maxim and all XJ650 Turbo, 1983 XJ750 Seca, 1983 XJ750 Maxim and Midnight Maxim models, and XJ900RK, RL, N/FN, and F models, use 2 per base, each:
$ 2.95

HCP14284 Aftermarket pick-up coils baseplate FLAT WASHER, black oxide-coated hardened alloy steel, for all 1983 XJ550, 1985 FJ600 models, 1983-4 XJ650 Maxim and all XJ650 Turbo, 1983 XJ750 Seca, 1983 XJ750 Maxim and Midnight Maxim models, and XJ900RK, RL, N/FN, and F models, use 2 per base, each:
$ 2.95



HCP315 OEM pick-up coils baseplate LOCK WASHER, for all XJ1100 Maxim models, use 2 per base. Each:
$ 3.95

HCP916 Aftermarket zinc-plated alloy steel with a natural finish, pick-up coils baseplate LOCK WASHER, for all XJ1100 Maxim models, use 2 per base. Each:
$ 1.95

HCP319 Aftermarket 18-8 stainless steel pick-up coils baseplate LOCK WASHER, for all XJ1100 Maxim models, use 2 per base. Each:
$ 2.95

HCP321 Aftermarket black oxide-coated alloy steel pick-up coils baseplate LOCK WASHER, for all XJ1100 Maxim models, use 2 per base. Each:
$ 1.95




NOTE: make sure that you do NOT pinch the lead wire harness as it is routed in-between the rear pick-up coils engine cover and the front of the shifter cover.....it is a very tight, constrained space where this harness is routed, and it is easy to pinch the wires, especially when removing and replacing the shifter cover.


HCP4180 OEM pick-up coils wiring lead harness CLAMP, u-shaped open clamp closest to the pick-up base. Use one on all XJ650, XJ700, XJ750, all XJ900RK, RL, N/FN, and F models, and two on XJ1100 models. Each:
$ 8.95

HCP4181 OEM pick-up coils wiring lead harness CLAMP, u-shaped open clamp farthest from the pick-up base. Use one on all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models. Each:
$ 7.95

HCP4183 OEM pick-up coils wiring lead harness CLAMP, flat L-shaped clamp that is attached at the front lower shifter cover bolt. Use one on all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models. Each:
$ 6.95





Pick-Up Coil Rotor ("Reluctor") Disc:

HCP497 OEM pick-up coils ROTOR DISC, for all XJ700 non-X models.
$ discontinued

HCP498 OEM pick-up coils ROTOR DISC, for all XJ700-X, XJ750-X, and XJ900RK, RL, N/FN, and F models.
$ discontinued


NOTE: the bolt that hold the reluctor to the crankshaft is lock-tighted in place, and we strongly suggest that you use a bit of heat to "loosen" the lock-tight when removing it (and re-use lock-tight when re-installing).

HCP505 OEM pick-up coils rotor disc MOUNTING BOLT, for all XJ550, FJ600, XJ650, XJ700, XJ750, and XJ900RK and RL models.
$ 7.95

HCP21944 Aftermarket pick-up coils rotor disc MOUNTING BOLT, alloy steel socket head cap screw with a black finish, For all XJ550, FJ600, XJ650, XJ700, XJ750, and XJ900RK and RL models.
$ 1.95

HCP21942 Aftermarket pick-up coils rotor disc MOUNTING BOLT, alloy steel socket head cap screw with a bright finish, For all XJ550, FJ600, XJ650, XJ700, XJ750, and XJ900RK and RL models.
$ 1.95

HCP23282 Aftermarket pick-up coils rotor disc MOUNTING BOLT, 18-8 stainless steel socket head cap screw with a bright finish, For all XJ550, FJ600, XJ650, XJ700, XJ750, and XJ900RK and RL models.
$ 2.95

HCP22203 Aftermarket pick-up coils rotor disc MOUNTING BOLT, 316 stainless steel socket head cap screw with a bright finish, For all XJ550, FJ600, XJ650, XJ700, XJ750, and XJ900RK and RL models.
$ 3.95

HCP23283 Aftermarket pick-up coils rotor disc MOUNTING BOLT, magni-coated (dull aluminum finish, ultra-corrosion resistance) alloy steel socket head cap screw. For all XJ550, FJ600, XJ650, XJ700, XJ750, and XJ900RK and RL models.
$ 3.95




Pick-Up Coil Timing Pointer:

NOTE: you should not find it necessary to ever move or remove the pointer; however, if that is necessary, upon replacement you will need to check and perhaps adjust and set the TDC of the engine and/or the engine timing. See your factory service or workshop manual for the proper procedure to check and/or adjust your ignition timing!


HCP314 OEM pick-up coils timing pointer MOUNTING SCREW, for all XJ550, XJ650, 1985 XJ700, XJ750 non-X, and XJ900RK models, use 1 per engine. Zinc-plated alloy steel, panhead, phillips-drive Each:
$ 3.95

HCP5335 OEM pick-up coils timing pointer MOUNTING SCREW, for all XJ550, XJ650, 1985 XJ700, XJ750 non-X, and XJ900RK models, use 1 per engine. Black alloy steel, panhead, phillips-drive. Each:
$ 8.95

HCP915 Aftermarket pick-up coils timing pointer MOUNTING SCREW, for all XJ550, XJ650, 1985 XJ700, XJ750 non-X, and XJ900RK models, use 1 per engine. Zinc-plated alloy steel, panhead, phillips-drive Each:
$ 1.95

HCP316 Aftermarket pick-up coils timing pointer MOUNTING SCREW, for all XJ550, XJ650, 1985 XJ700, XJ750 non-X, and XJ900RK models, use 1 per engine. 18-8 stainless steel, panhead, phillips-drive. Each:
$ 2.95

HCP317 Aftermarket pick-up coils timing pointer MOUNTING SCREW, for all XJ550, XJ650, 1985 XJ700, XJ750 non-X, and XJ900RK models, use 1 per engine. 18-8 stainless steel with a polished button head, hex-drive. Each:
$ 2.95

HCP318 Aftermarket pick-up coils timing pointer MOUNTING SCREW, for all XJ550, XJ650, 1985 XJ700, XJ750 non-X, and XJ900RK models, use 1 per engine. 18-8 stainless steel with a smooth, polished socket head, hex-drive. Each:
$ 2.95

HCP320 Aftermarket pick-up coils timing pointer MOUNTING SCREW, for all XJ550, XJ650, 1985 XJ700, XJ750 non-X, and XJ900RK models, use 1 per engine. Black-oxide coated alloy steel with a ribbed socket head. Each:
$ 1.95



HCP2173 OEM pick-up coils timing pointer FLAT WASHER, for all XJ550 models, use 1 per engine, original bright finish, each:
$ 2.95

HCP6642 Aftermarket pick-up coils timing pointer FLAT WASHER, zinc-plated alloy steel with a natural finish, for all XJ550 models, use 1 per engine, each:
$ 1.95

HCP6643 Aftermarket pick-up coils timing pointer FLAT WASHER, 18-8 stainless steel with a natural finish, for all XJ550 models, use 1 per engine, each:
$ 2.95

HCP25756 Aftermarket pick-up coils timing pointer FLAT WASHER, 316 stainless steel with a natural finish, for all XJ550 models, use 1 per engine, each:
$ 3.95

HCP14285 Aftermarket pick-up coils timing pointer FLAT WASHER, black oxide-coated 18-8 stainless steel, for all XJ550 models, use 1 per engine, each:
$ 2.95

HCP14284 Aftermarket pick-up coils timing pointer FLAT WASHER, black oxide-coated hardened alloy steel, for all XJ550 models, use 1 per engine, each:
$ 2.95



HCP3575 OEM pick-up coils timing pointer FLAT WASHER, for all XJ650, 1985 XJ700, XJ750, and XJ900RK, RL, and N/FN models, use 1 per engine. Each:
$ 6.95

HCP6642 Aftermarket pick-up coils timing pointer FLAT WASHER, zinc-plated alloy steel with a bright finish, for all XJ650, 1985 XJ700, XJ750, and XJ900RK, RL, and N/FN models, use 1 per engine. Each:
$ 1.95

HCP6643 Aftermarket pick-up coils timing pointer FLAT WASHER, 18-8 stainless steel with a bright finish, for all XJ650, 1985 XJ700, XJ750, and XJ900RK, RL, and N/FN models, use 1 per engine. Each:
$ 2.95

HCP25756 Aftermarket pick-up coils timing pointer FLAT WASHER, 316 stainless steel with a dull finish, for all XJ650, 1985 XJ700, XJ750, and XJ900RK, RL, and N/FN models, use 1 per engine. Each:
$ 3.95

HCP14285 Aftermarket pick-up coils timing pointer FLAT WASHER, black oxide-coated 18-8 stainless steel, for all XJ650, 1985 XJ700, XJ750, and XJ900RK, RL, and N/FN models, use 1 per engine. Each:
$ 2.95

HCP14284 Aftermarket pick-up coils timing pointer FLAT WASHER, black oxide-coated hardened alloy steel, for all XJ650, 1985 XJ700, XJ750, and XJ900RK, RL, and N/FN models, use 1 per engine. Each:
$ 2.95



HCP315 OEM pick-up coils timing pointer LOCK WASHER, for all XJ550 models, use 1 per engine. Each:
$ 3.95

HCP916 Aftermarket zinc-plated alloy steel with a natural finish, pick-up coils timing pointer LOCK WASHER, for all XJ550 models, use 1 per engine. Each:
$ 1.95

HCP319 Aftermarket 18-8 stainless steel pick-up coils timing pointer LOCK WASHER, for all XJ550 models, use 1 per engine. Each:
$ 2.95

HCP321 Aftermarket black oxide-coated alloy steel pick-up coils timing pointer LOCK WASHER, for all XJ550 models, use 1 per engine. Each:
$ 1.95




ec2) OEM oil pump/crankshaft end cover ("YICS covers" on models so equipped) COVER GASKET. A great idea to replace these if you remove the case covers. Although these gaskets don't seal any fluids, you don't really want grime and gunk and junk accumulating inside the covers.

OEM oil pump cover gaskets are made from a standard duty, graphite impregnated paper material. We recommend the use of the aftermarket hi-performance paper gaskets which are designed to slightly swell in the presence of petroleum products (fuel or oil), thus creating a super-tight, leak-proof flange seal.


HCP998 OEM oil pump covers or "YICS" covers standard duty paper GASKET. Originally used under the left side cover only, but many people like to install one under the right side cover also, and they will fit either side properly. Fits all XJ550, FJ600, XJ650, 1981-83 all XJ750 models, XJ750RL, and all XJ900RK, RL, N/FN, and F models. Each:
$ 14.95

HCP998SET2 OEM oil pump covers or "YICS" covers standard duty paper GASKETS, set of 2:
$ 27.95


HCP18438 Aftermarket oil pump covers or "YICS" covers hi-performance GASKET. Originally used under the left side cover only, but many people like to install one under the right side cover also, and they will fit either side properly. Fits all XJ550, FJ600, XJ650, 1981-83 all XJ750 models, XJ750RL, and all XJ900RK, RL, N/FN, and F models. Each:
$ 12.95

HCP18438SET2 Aftermarket oil pump covers or "YICS" covers hi-performance GASKETS, set of 2:
$ 24.95



HCP999 OEM crankshaft end cover-to-block rubber RING GASKET, fits all 1986-88 FZ600, 1986-90 YX600 Radian, all XJ700, XJ750-X, 1984-85 FJ1100, and 1986-93 FJ1200 models. Right and left side are the same. Each:
$ 32.95

HCP999SET2 OEM crankshaft end cover-to-block RING GASKETS, set of 2:
$ 62.95


HCP25160 Aftermarket crankshaft end cover-to-block rubber RING GASKET, fits all 1986-88 FZ600, 1986-90 YX600 Radian, all XJ700, XJ750-X, 1984-85 FJ1100, and 1986-93 FJ1200 models. Right and left side are the same. Each:
$ 19.95

HCP25160SET2 Aftermarket crankshaft end cover-to-block RING GASKETS, set of 2:
$ 37.95




HCP5795 OEM "YICS" or "DOHC" cover-to-block rubber RING GASKET, fits all XJ750 Midnight Maxim, XJ750RL, and all XJ900RK, RL, N/FN, and F models. Right and left side are the same. Each:
$ 39.75



HCP1001 OEM "YICS" cover-to-block standard duty paper GASKET, fits all XJ1100 and XS1100 models. Used on the left side only. Each:
$ 29.95

HCP18439 Aftermarket "YICS" cover-to-block hi-performance GASKET, fits all XJ1100 and XS1100 models. Used on the left side only. Each:
$ 22.95




TCI UNITS:

Yamaha (thankfully!) used a TCI (which stands for Transistor Controlled Ignition) system on all XJ-series bikes to control the coils, timing, spark advance, etc. A TCI unit is an "early" version of the now-common electronic control systems that are used on virtually all modern vehicles of almost every type, and even these early versions are completely maintenance-free and very rarely cause problems...........which is a good thing, because original TCI boxes are no longer available new.

When engine performance problems develops, many people immediately suspect that the cause may be within the "black box" workings of their TCI unit, which is unlikely. The factory service manual gives "instructions" for diagnosing TCI problems, and it basically says "test every other possible cause for your problem and if no other cause for the problem exists, only then should you "suspect" TCI failure, but before you buy a replacement, first try to find a known, working TCI unit from a similar bike and plug it in on the problem bike, and see if the problem goes away............"

Well!

There are three main problems that TCI units succumb to after years of reliable service:

1) bad solder joints on some of the internal components (known as "cold solder joints") result in the component pieces coming loose from the circuit board, and thus they can no longer perform their function reliably (or at all).

2) component failure......a blown-up transistor, a burned circuit trace, etc. This situation can develop if you have a short-circuit in your electrical system, or hook up your battery or jumper cables incorrectly, etc. TCI units do not like "big blue sparks" in the electrical system (except at the spark plugs, of course!).

3) another common failure of these units occurs if the TCI is continuously grounding the ignition coil (i.e. its output driver is shorted). You can verify this situation with an ohmmeter with the following tests:

- disconnect the 2-pin plug at the ignition coil and measure from the orange or grey wire to the chassis. You should see very high resistance. This should be pretty close on both the working and non-working channels.

- if you read a few ohms of resistance or less, then the TCI is bad. A shorted driver will also make the ignition coil run very hot and may ruin the coil.

4) dirty terminal connections.....clean them with electrical contact cleaner and/or miniature wire brushes or files. NOTE: sometimes the mere act of unplugging and plugging back in the connectors to the TCI unit can resolve a “dirty connectors” issue (at least, temporarily)


Bad solder joints can be repaired by someone who is skilled at that sort of diagnosis and repair, and even individual circuit components can be replaced, but it's tough to find someone in the modern world of "pitch-and-plug" skill-sets who actually has the skill and patience to do this type of work. Yamaha gave absolutely "zero" electrical specifications for checking the condition of the TCI units, besides the afore-mentioned "check everything else first" type of diagnosis.

But you can perform a simple set of tests to determine whether your TCI unit is good or not, without having a second, known good unit to install in place of the suspect unit. Although these instructions were written for XS owners, the exact same thoughts apply to the TCI units on the XJ-series of bikes:

Whoops! Unfortunately the link to that page is dead, but here are the written instructions. It does require an analog meter, as digital multi-meters do not show the swing of the needle that is required to test it.

"Using a voltmeter set on 12VDC, connect the positive meter lead to the Orange or the Grey pick-up coil lead at the TCI. Connect the negative meter lead to the black (negative) lead at the TCI. Turn on the ignition. Voltage should come right up to about 10 - 11VDC. Crank the ignition and observe the meter. Look for a wide voltage swing during cranking. A strong swing indicates that the pickups and TCI are working OK and your trouble is between the TCI and the plugs. Possibly a bad ballast resistor (XS1100 models only) , bad coil, bad plug cap or just corroded connections. Repeat this test for both Orange and Grey coil leads."

Remember that the Red wire with the white tracer stripe should always be hot with the key on. The TCI unit grounds the gray and orange wires from the ignition coils. The ignition coils fire when the TCI interrupts the ground.

The tricky part is the TCI un-grounds the gray and orange if there is no signal from the pick-up coils for a few seconds. This is to protect the coils from overheating if the key is on and the engine isn't running. So unless you check the Red/white wire to gray (or orange) really quickly, you might get false readings or a mis-diagnosis of the true nature of the problem.


All of the XJ-series TCI units are of the "4R0" style as described in the above article.


And if the above isn't enough, if you feel the need to get medieval with your TCI unit, well, then it doesn't get much better than this:

http://www.jetav8r.com/Vision/IgnitionFAQ.html

and this:

http://xjbikes.com/forums/threads/old-yamaha-diodes.32519


And for those who just can't resist a good Resistor (or transistor), here you go:

http://xjbikes.com/forums/index.php?threads/37190

and Holy Dark Mother of Fibre, don't try this at home kids!:

http://xjbikes.com/forums/index.php?threads/38234


One of the peculiarities of the TCI is the need to have at least one ground path for each secondary coil winding when checking for spark, or the TCI could (more like will) be damaged. For that reason you should never have more than one spark plug wire disconnected at any one time while cranking, and check for spark one plug at a time by grounding the plug to the head.

In a situation where you would want all plugs out…….for example, compression testing of the engine……then it is recommended that the TCI be unplugged from the main harness before testing is undertaken.


By the way, the TCI needs a minimum of about 10VDC to operate......and while the starter will spin the engine over like mad with low voltage, the TCI falls on its face at less than 10 volts.....which can lead to all sorts of confusion when a battery low-voltage condition occurs!




TCI Case Hardware:

Some TCI units have removable case covers to allow internal inspection of the circuit board. Over time these screws can get pretty foul-looking; if you want to restore the appearance of your unit, these (along with the replacement decal) will give your old unit and nice, "like-new" appearance. NOTE: not all TCI units had removable faceplates; it seems that sometime in the mid-80's, TCI units were produced with electronically welded cases, and not dis-assembly is possible (or at least "easy").


HCP6111 OEM tci case self-tapping SCREW. Used to hold the TCI case cover to the main body of the case. Use 4 per TCI on all XJ550, FJ600, XJ650RJ Seca, XJ750, and XJ900 models. These screws have a black finish as original. Each:
$ 4.95

HCP6111SET4 OEM tci case self-tapping SCREWS, set of 4:
$ 18.95


HCP28331 Aftermarket tci case self-tapping SCREW. Used to hold the TCI case cover to the main body of the case. Use 4 per TCI on all XJ550, FJ600, XJ650RJ Seca, XJ750, and XJ900 models. These screws are made from 18-8 stainless steel and have a bright finish. Each:
$ 2.95

HCP28331SET4 OEM tci case self-tapping SCREWS, set of 4:
$ 9.95


HCP28329 Aftermarket tci case self-tapping SCREW. Used to hold the TCI case cover to the main body of the case. Use 4 per TCI on all 1980-81 XJ650 Maxim and Midnight Maxim models (with the black label that reads 4H7-10, Type TID14-02). These screws are made from 4140 stainless steel and have a bright finish. Each:
$ 3.95

HCP28329SET4 OEM tci case self-tapping SCREWS, set of 4:
$ 14.95


HCP28327 Aftermarket tci case self-tapping SCREW. Used to hold the TCI case cover to the main body of the case. Use 4 per TCI on all XJ650 Turbo models. These screws are made from 410 stainless steel and have a bright finish. Each:
$ 3.95

HCP28327SET4 OEM tci case self-tapping SCREWS, set of 4:
$ 14.95




HCP6113 OEM tci case self-tapping SCREW. Used to hold the TCI case cover to the main body of the case. Use 6 per TCI on all XJ1100 models. These screws have a bright finish as original. Each:
$ 4.95

HCP6113SET6 OEM tci case self-tapping SCREWS, set of 6:
$ 27.95


HCP28333 Aftermarket tci case self-tapping SCREW. Used to hold the TCI case cover to the main body of the case. Use 6 per TCI on all XJ1100 models. These screws have a bright finish as original. Each:
$ 1.95

HCP28333SET2 Aftermarket tci gauge cluster housing self-tapping SCREWS, set of 2:
$ 2.95




TCI Mounting Hardware:

er5) All of the little SCREWS, WASHERS, & NUTS needed to properly mount the TCI units to their foundation.

HCP314 OEM TCI - Igniter Unit mounting SCREW, user 2 per unit. For all XJ550 and FJ600 models. Zinc-plated alloy steel, panhead, phillips-drive Each:
$ 3.95

HCP5335 OEM TCI - Igniter Unit mounting SCREW, user 2 per unit. For all XJ550 and FJ600 models. Black alloy steel, panhead, phillips-drive. Each:
$ 8.95

HCP915 Aftermarket TCI - Igniter Unit mounting SCREW, user 2 per unit. For all XJ550 and FJ600 models. Zinc-plated alloy steel, panhead, phillips-drive Each:
$ 1.95

HCP316 Aftermarket TCI - Igniter Unit mounting SCREW, user 2 per unit. For all XJ550 and FJ600 models. 18-8 stainless steel, panhead, phillips-drive. Each:
$ 2.95

HCP317 Aftermarket TCI - Igniter Unit mounting SCREW, user 2 per unit. For all XJ550 and FJ600 models. 18-8 stainless steel with a polished button head, hex-drive. Each:
$ 2.95

HCP318 Aftermarket TCI - Igniter Unit mounting SCREW, user 2 per unit. For all XJ550 and FJ600 models. 18-8 stainless steel with a smooth, polished socket head, hex-drive. Each:
$ 2.95

HCP320 Aftermarket TCI - Igniter Unit mounting SCREW, user 2 per unit. For all XJ550 and FJ600 models. Black-oxide coated alloy steel with a ribbed socket head. Each:
$ 1.95



HCP1030 OEM TCI - Igniter Unit mounting SCREW, dark finish alloy steel, panhead, phillips drive. Use 2 per unit. For all XJ650 models, all XJ700 models, all XJ750 models, and all XJ900RK, RL, N/FN, and F models. Each:
$ 7.95

HCP2922 Aftermarket TCI - Igniter Unit mounting SCREW, use 2 per unit. For all XJ650 models, all XJ700 models, all XJ750 models, and all XJ900RK, RL, N/FN, and F models. Zinc-plated alloy steel, natural finish, panhead phillips-drive, each:
$ 2.95

HCP21362 Aftermarket TCI - Igniter Unit mounting SCREW, use 2 per unit. For all XJ650 models, all XJ700 models, all XJ750 models, and all XJ900RK, RL, N/FN, and F models. 18/8 stainless steel, bright finish, panhead phillips-drive, each:
$ 3.95

HCP6714 Aftermarket TCI - Igniter Unit mounting SCREW, use 2 per unit. For all XJ650 models, all XJ700 models, all XJ750 models, and all XJ900RK, RL, N/FN, and F models. Button head hex-drive, 18-8 stainless steel, bright finish, each:
$ 3.95

HCP6715 Aftermarket TCI - Igniter Unit mounting SCREW, use 2 per unit. For all XJ650 models, all XJ700 models, all XJ750 models, and all XJ900RK, RL, N/FN, and F models. Socket head, hex-drive, black-oxide coated alloy steel, each:
$ 2.95

HCP6716 Aftermarket TCI - Igniter Unit mounting SCREW, use 2 per unit. For all XJ650 models, all XJ700 models, all XJ750 models, and all XJ900RK, RL, N/FN, and F models. Socket head, hex-drive, 18-8 stainless steel, bright finish, each:
$ 3.95



HCP3860 OEM TCI - Igniter Unit mounting SCREW, user 2 per unit. For all XJ1100 models. Each:
$ 1.50



HCP315 OEM TCI - Igniter mounting LOCK WASHER, use 2 per unit. Fits all FJ600, XJ650, XJ750, XJ900RK, RL, N/FN, and F models, and XJ1100 models. Each:
$ 3.95

HCP916 Aftermarket zinc-plated alloy steel with a natural finish, TCI - Igniter mounting LOCK WASHER, use 2 per unit. Fits all XJ650, XJ750, XJ900RK, RL, N/FN, and F models, and XJ1100 models. Each:
$ 1.95

HCP319 Aftermarket 18-8 stainless steel TCI - Igniter mounting LOCK WASHER, use 2 per unit. Fits all XJ650, XJ750, XJ900RK, RL, N/FN, and F models, and XJ1100 models. Each:
$ 2.95

HCP321 Aftermarket black oxide-coated alloy steel TCI - Igniter mounting LOCK WASHER, use 2 per unit. Fits all XJ650, XJ750, XJ900RK, RL, N/FN, and F models, and XJ1100 models. Each:
$ 1.95



HCP2173 OEM TCI - Igniter mounting FLAT WASHER, use 2 per unit. Fits all XJ550, FJ600, XJ650 except 1983 XJ650 Turbo, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models, original bright finish, each:
$ 2.95

HCP6642 Aftermarket TCI - Igniter mounting FLAT WASHER, zinc-plated alloy steel with a natural finish, use 2 per unit. Fits all XJ550, FJ600, XJ650 except 1983 XJ650 Turbo, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models, each:
$ 1.95

HCP6643 Aftermarket TCI - Igniter mounting FLAT WASHER, 18-8 stainless steel with a natural finish, use 2 per unit. Fits all XJ550, FJ600, XJ650 except 1983 XJ650 Turbo, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models, each:
$ 2.95

HCP25756 Aftermarket TCI - Igniter mounting FLAT WASHER, 316 stainless steel with a natural finish, use 2 per unit. Fits all XJ550, FJ600, XJ650 except 1983 XJ650 Turbo, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models, each:
$ 3.95

HCP14285 Aftermarket TCI - Igniter mounting FLAT WASHER, black oxide-coated 18-8 stainless steel, use 2 per unit. Fits all XJ550, FJ600, XJ650 except 1983 XJ650 Turbo, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models, each:
$ 2.95

HCP14284 Aftermarket TCI - Igniter mounting FLAT WASHER, black oxide-coated hardened alloy steel, use 2 per unit. Fits all XJ550, FJ600, XJ650 except 1983 XJ650 Turbo, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models, each:
$ 2.95



HCP4248 OEM TCI - Igniter mounting FLAT WASHER, bright zinc-plated alloy steel, use 2 per unit. Fits all 1983 XJ650 Turbo models. Each:
$ 3.95

HCP25871 Aftermarket TCI - Igniter mounting FLAT WASHER, bright zinc-plated alloy steel, use 2 per unit. Fits all 1983 XJ650 Turbo models. Each:
$ 1.95



HCP1903 OEM TCI - Igniter mounting FLAT WASHER, black oxide-coated alloy steel, use 2 per unit. Fits all XJ1100 models, front side of the TCI. Each:
$ 3.95

HCP25872 Aftermarket TCI - Igniter mounting FLAT WASHER, bright zinc-plated alloy steel, use 2 per unit. Fits all XJ1100 models, front side of the TCI. Each:
$ 1.25

HCP25873 Aftermarket TCI - Igniter mounting FLAT WASHER, bright 18/8 stainless steel, use 2 per unit. Fits all XJ1100 models, front side of the TCI. Each:
$ 1.75

HCP25875 Aftermarket TCI - Igniter mounting FLAT WASHER, black oxide-coated 18/8 stainless steel, use 2 per unit. Fits all XJ1100 models, front side of the TCI. Each:
$ 1.95

HCP25874 Aftermarket TCI - Igniter mounting FLAT WASHER, bright 316 stainless steel, use 2 per unit. Fits all XJ1100 models, front side of the TCI. Each:
$ 2.95



HCP3575 OEM ignition TCI - Igniter box mounting FLAT WASHER, use 2 per unit. Fits all XJ1100 models, rear side of the TCI. Each:
$ 6.95

HCP6642 Aftermarket ignition TCI - Igniter box mounting FLAT WASHER, zinc-plated alloy steel with a bright finish, use 2 per unit. Fits all XJ1100 models, rear side of the TCI. Each:
$ 1.95

HCP6643 Aftermarket ignition TCI - Igniter box mounting FLAT WASHER, 18-8 stainless steel with a bright finish, use 2 per unit. Fits all XJ1100 models, rear side of the TCI. Each:
$ 2.95

HCP25756 Aftermarket ignition TCI - Igniter box mounting FLAT WASHER, 316 stainless steel with a dull finish, use 2 per unit. Fits all XJ1100 models, rear side of the TCI. Each:
$ 3.95

HCP14285 Aftermarket ignition TCI - Igniter box mounting FLAT WASHER, black oxide-coated 18-8 stainless steel, use 2 per unit. Fits all XJ1100 models, rear side of the TCI. Each:
$ 2.95

HCP14284 Aftermarket ignition TCI - Igniter box mounting FLAT WASHER, black oxide-coated hardened alloy steel, use 2 per unit. Fits all XJ1100 models, rear side of the TCI. Each:
$ 2.95



HCP3996 OEM TCI - Igniter mounting NUT, alloy steel with a bright zinc-plated finish. Use 2 per unit. Fits all XJ650 (except Turbo) models, all XJ700 models, and all XJ750 models. Each:
$ 8.95

HCP16570 Aftermarket TCI - Igniter mounting NUT, 18/8 stainless steel with a bright zinc-plated finish. Use 2 per unit. Fits all XJ650 (except Turbo) models, all XJ700 models, and all XJ750 models. Each:
$ 2.95


HCP4247 OEM TCI - Igniter mounting NUT PLATE, use 2 per unit. Fits all XJ550, XJ650 Turbo, and all XJ900RK, RL, N/FN, and F models. Each:
$ discontinued



TCI (Igniter) Case ID Decals:

HCP8107 Aftermarket TCI case ID DECAL, blue foil decal with TID14-05, 4U8-10 wording. Used on all XJ550 model TCI (igniter) boxes. NOTE: the silver "date code" box is left blank/unstamped.
$ 12.95

HCP8108 Aftermarket TCI case ID DECAL, black foil decal with TID14-02, 4H7-10 wording. Used on all 1980-81 XJ650 Maxim and Midnight Maxim model TCI (igniter) boxes. NOTE: the silver "date code" box is left blank/unstamped.
$ 12.95

HCP8109 Aftermarket TCI case ID DECAL, green foil decal with TID14-08, 5V2-10 wording. Used on all 1982 XJ650RJ Seca model TCI (igniter) boxes. NOTE: the silver "date code" box is left blank/unstamped.
$ 12.95

HCP8111 Aftermarket TCI case ID DECAL, black foil decal with TID14-13, 16G-10 wording. Used on all 1982-83 XJ650 Turbo model TCI (igniter) boxes. NOTE: the silver "date code" box is left blank/unstamped.
$ 12.95

HCP8110 Aftermarket TCI case ID DECAL, red foil decal with TID14-06, 5G2-10 wording. Used on all 1982-83 XJ650 Maxim and 1981-83 XJ750 models TCI (igniter) boxes. NOTE: the silver "date code" box is left blank/unstamped.
$ 12.95

HCP8112 Aftermarket TCI case ID DECAL, red foil decal with TID14-44, 1FG-10 wording. Used on all 1985-86 XJ700 air-cooled model TCI (igniter) boxes. NOTE: the silver "date code" box is left blank/unstamped.
$ 12.95

HCP8113 Aftermarket TCI case ID DECAL, yellow foil decal with TID14-35, 1AA-10 wording. Used on all 1985-86 XJ700-X water-cooled model TCI (igniter) boxes. NOTE: the silver "date code" box is left blank/unstamped.
$ 12.95

HCP8114 Aftermarket TCI case ID DECAL, black foil decal with TID14-19, 31A-10 wording. Used on all 1983-84 XJ900RK and RL model TCI (igniter) boxes. NOTE: the silver "date code" box is left blank/unstamped.
$ 12.95

HCP8115 Aftermarket TCI case ID DECAL, black foil decal with TID14-10, 10M-10 wording. Used on all 1982-84 XJ1100 Maxim and Midnight Maxim model TCI (igniter) boxes. NOTE: the silver "date code" box is left blank/unstamped.
$ 12.95