Announcement

Collapse
No announcement yet.

wiring harnesses

Collapse
X
 
  • Filter
  • Time
  • Show
Clear All
new posts

  • wiring harnesses

    I'm currently knees deep in my first XS project. I was given an '80 G My grandpa's, and he had parked it in the garage for about 10 years. The motor on it needed completely rebuilt thanks to my cousin removing three plugs, breaking off the fourth and then just leaving the block exposed to outside air for a few years. Midway through tear-down on that machine, I found a '79 Special in a nearby town for only $300.

    I rebuilt the carbs, and it runs like a champ... Only, someone got into the electrical. there's a toggle switch down by the fuses that acts as the kill switch. None of the lights work. Tach quit working. Battery is not charging (new battery went dead a few rides). And, there's a wire in one of the Ignition Unit connectors that shorts out when you look at it wrong.

    My question to the XS veterans on the forum here is this:
    Would I be able to swap the harness from the '80Gto the '79SF?

    I've done some studying, and the wiring diagrams are very similar. It looks like I would possibly have to use the instrument cluster from the '80 and the handlebar controls on the '79 are tore up and I could use the ones off the '80 for that as well.

    I've searched the forum quite a bit trying to see if someone has already addressed this issue. If I'm treading on old ground, I apologize, and I'd appreciate a link to the discussion.
    Last edited by jmyers40; 06-07-2008, 05:51 PM.
    79 XS1100 Special - slowing breathing life back into it...

  • #2
    I just went through the hassle because someone sent me a wrong harness.I studied the wiring diagrams in the manuals and online and am missing half the connectors that plug into things in the headlight bucket.Perhaps you know about electrical connections more than myself, but i think that you are going to be in store for something that you might not want to mess with IMHO.Good luck!
    1980 XS1100 SG
    Inline fuel filters
    New wires in old coils-outer spark plugs
    160 mph speedometer mod
    Kerker Exhaust
    xschop K & N air filter setup
    Dynojet Recalibration kit
    1999 Kawasaki ZRX1100
    1997 Jeep Cherokee 4.5"lift installed

    Comment


    • #3
      Sounds like your regulator or your alternator is not working .As for your harness check the connector at the ignition box mine did the same I just cleaned it and it was fine. If the toggle switch isn't a problem leave it or take it out. That would be a lot easier than replacing the harness.
      BDF Special
      80SG Vetter bagger 1196 Wiseco big bore kit, Mega Cycle Cams, slotted cam gears, ported and flowed head, bronze intake seats, Dyno Jet kit, Dyno coils and Mikes XS air pods, Venture cam chain adjuster,Geezer's regulator, Clutch mod, Mac 4 into 1 with custom built and tuned baffle, Oil cooler,MikesXS emulators mod.
      Dyno tuned to 98 hp at the rear wheel.

      Comment


      • #4
        None of the lights work. Tach quit working. Battery is not charging (new battery went dead a few rides). And, there's a wire in one of the Ignition Unit connectors that shorts out when you look at it wrong.
        Takes a few hours, but cleaning ALL the electrical connectors and grounds on a newly acquired XS is a good idea and may solve most of your problems. Behind the fuse block there are three white connectors. These seem to get over looked and one in particular carries power from the generator and has been known to get hot enough to melt the plug. The tack gets it's signal from the generator too and there's a line to the head light relay that activates the relay from the generator.
        Once connectors are clean then can start trouble shooting specific problems.


        mro
        BTW, welcome to XS land

        Comment


        • #5
          Thanks for all the help folks. I got curious and took out the headlight; the bulb was blown. I notice it shares a ground with a LOT of other components...

          Just to clarify, the regulator is the little mysterious guy under the the tank right? I think I'm gonna bite the bullet and clean all the connections this coming Thursday. What's the best tools you've found for cleaning everything? Emory board? scouring pad? wire brush?
          79 XS1100 Special - slowing breathing life back into it...

          Comment


          • #6
            Hey Myers,

            Take a look at THIS THREAD , has info on what to use for cleaning, as well as different types of dielectric grease to use afterwards!

            Yes, Reg/Rect is under gastank near the seat area, it grounds to the frame thru the securing bolts, to take them off to clean contacts to frame for better grounding.

            There's a large grounding strap at the rear of the engine that secures to the frame below the battery area, another spot that is often missed!

            And remember to disconnect the battery before working on things, disconnecting the (-) negative cable FIRST !

            See...DiverRay..this old dog CAN learn new tricks! I had just never been taught that technique. I had just removed the (+) First, because that's where the "Juice" comes from and so I wanted to disconnect it....but I "now" understand the safety aspect of removing the (-) first so as to not accidentally GROUND/SHORT a tool or something to the (+) terminal of the battery and the Frame with the GROUND(-) still connected!

            T.C.
            T. C. Gresham
            81SH "Godzilla" . . .1179cc super-rat.
            79SF "The Teacher" . . .basket case!
            History shows again and again,
            How nature points out the folly of men!

            Comment


            • #7
              Harness change

              Hi, I had the electrical blues with my '79 SF. Weak battery, hard starting and hated getting wet caused many frustrating times for me. The PO had butchered the wiring in the headlight as well with a multitude of single connectors instead of half a dozen multiplugs inside. My spare bike, '78E donated it's harness and everything went in really well. I noticed, as I was disconnecting the alternator wiring that the connector was melted together (hidden down behind the frame/footpeg/brake pedal, I'd missed it altogether) so a very close inspection of all connectors should be done before diving in head first. I changed the instrument cluster as well so I could have the fuel guage and all the handlebar switchgear plugged straight in. The only bit that took a bit of sorting out was the front indicators, which on the special, are single filament bulbs, and the wiring for the '78E which was supposed to twin filament bulbs to allow for running lights in the blinkers. Once identified, I just tucked away the extra live wires for the runners and ran some new earths for the blinkers.
              Hasn't missed a beat since then.
              Regards,
              Errol
              79 SF Special W/ Stock all original motor @ 384,000klms
              Stock exhaust, stock airbox, XJ sump, 78E carbs, Xs1100RH seat, Bosch superhorns, 5/8ths front M/c, braided lines, sintered SBS pads, drilled discs, progressive springs, 8" 50w HID headlight 4300K, 2 x 50w HID spiral driving lights, KONI shocks, Spade fuse box
              *Touring mode - Plexistar 2 screen, Gearsack rack & bag & saddlebags, homebuilt towbar
              *"The Keg"- UC torana hubs, XS11 discs, Tokico 4 spot calipers

              Comment


              • #8
                Thanks again for the help. I'll have to pick up the grease and bore brushes from Wallymart today or tomorrow, then get started next Thursday when I have 4 days off. I'll let you all know how it works out.
                79 XS1100 Special - slowing breathing life back into it...

                Comment


                • #9
                  Rrrrrrr

                  After some work on it tonight, I found A problem that was causing the bike to die at will. One of the wires in the small connector on the ignition unit was barely hangin on (broke off when I pulled the connector out. (no, I didn't pull it out by the wires either, ha) I'm wondering what the feasability of replacing all the ends of the wires with proper (soldered, not crimped) ends would be??? Anyone done that? I'm sure someone has posted about it somewhere on here. I'll update after the next time I work on the bike.

                  I started at the back, didn't even make it halfway tonight :-(
                  79 XS1100 Special - slowing breathing life back into it...

                  Comment

                  Working...
                  X