On Any Sunday -- correcting a 1980 XS1100G schematic

[3Phase]

All of the schematics I have - online copies and the Yamaha shop manual - are wrong and/or incomplete.

Everything from wires shown in the wrong color and incorrectly marked junctions to entire components and terminals missing and terminals and components shown that are not actually present on my bike.

Since I have the wiring harness out and completely stripped down I corrected a schematic to reflect what I have on my US model 1980 XS1100G.

Here is a link to a legible copy (2048 x 1536) @ 367KB

http://farm4.static.flickr.com/3012/...261a11_o_d.jpg



For entertainment purposes only!
Almost banned in Boston!
#include <std_disclaimers.h>


Regards,

Scott

[Jerry]

Nice job, Scott!

[tjhummer]

Nice job!

I have been working with a headlight and tach problems and I had concluded from the diagram in the Clymer book that they both were both controlled by the same winding off the stator. I was finding conflicting real-world evidence that said it might not be so. I see by your diagram that you found them on separate windings. This would answer a couple of questions about why my findings confliced with the book.

[3Phase]

Rev. 02

Thanks, Jerry!

tjhummer, I found a lot of inconsistent readings and other things that made no sense.

To get home when my bike died I removed the headlight fuse; charging circuit could have been flakey and the battery low. When I got home, the headlight was on and shining brightly on the back wall of the garage and it got brighter when I revved the engine. Apparently the charging circuit is working just fine and my Reserve Lighting Device can reserve a headlight circuit right around a missing headlight fuse. <scratching head>

When I discovered that the wires on my bike didn't really match the schematics I had to pull the harness to troubleshoot the schematics, too.


Errors I found and corrected in the schematic Rev. 01:

Hazard flasher wire connections reversed at the two-prong flasher connector and the wrong color.

Right handlebar switch wires for the headlight on/off switch are not present on my bike.

Internal right handlebar switch diagrams missing.

Headlight relay diode and tachometer do NOT share a common alternator winding. It is possible this could vary from harness to harness, but I am not going to tear into any more wiring harnesses to find out.

Small R/Y wire to the TCI from the starter solenoid connects with a green wire from the N.O. (motor/load) terminal of the starter solenoid.

One horn missing.

Neutral switch missing.

No fuse box circuit labels and no fuse amperages.


Rev. 02

Since my initial post I have found another error in the schematic.

The Brown/White wire at the left handlebar switch was mislabeled as a Black/White wire at the connector. The correct color (Br/W) is shown in the switch function block diagram.

<sigh> I've uploaded a revised copy.

http://farm4.static.flickr.com/3247/...3b142c_o_d.jpg




To Do:

Add a 30 Amp label to the Main fuse in the schematic.

Add the unconnected yellow wire from the alternator that is present at the alternator-to-harness connector located behind the fuse box.

Add and show the second ground terminal at the regulator/rectifier because there are two separate ground circuits that connect to one another at that point. It should, in theory, make troubleshooting easier by dividing the entire ground circuit in half, but I need mark the two halves after determining what goes to ground through which circuit and when it does it.

Add the internal wires/connections for the instrument cluster and other devices that are not fully illustrated in the schematic.

Add what, exactly, each fuse is supposed to protect.

Triple-czech for errors.

Make a full-color version of the schematic.

That should keep me out of trouble for a while!


Regards,

Scott

[tjhummer]

Mind reader

I was just going to ask about a color version. You must have read my mind. I don't really have any trouble reading a black and white one, but color is just sooooo nice. Thanks for all the work you have done so far. It is very nicely done.

[81xsproject]

I found a big problem with the clutch switch. Book says it goes to the iggy box. But that wire isn't at the iggy box.

[3Phase]

I don't have a clutch switch or any other safety lockouts. There weren't any installed on a 1980 1100G.

I can drive right up to the edge of the Grand Canyon and stop, pop a cold beverage, then hit the starter button to leave while in gear with the clutch out and the sidestand down and enjoy the full-throated roar of my finely crafted and lovingly tuned 1101cc engine as it accelerates gleefully toward the Colorado River.



Regards,

Scott

[oldnortonrider]

I have the Yamaha shop manual and Clymer's manual; am I to understand, the schematics have many errors? I, also, have been mystified that they don't show the amp ratings of the fuses in the fuse block.

?-is there a reason, I can't get the pics to come up on this thread, showing your schematic corrections?

("flickr"?)

[3Phase]

Deleted

Yes, the factory manual has a lot of errors in the schematic for the 1980 XS1100G (Standard). I haven't seen Clymer's or Haynes' so I can't say if they're accurate or not.

This is an older thread and I didn't like using Flickr to host the images. I deleted the old black and white image from my Flickr account that was linked to this thread and started a new thread.

Color XS1100G USA Schematic

has the latest full-color schematic and the image is stored on my free webspace instead of Flickr.

Download the 140K Version, not the small 64K display image like this:




Regards,

Scott

[oldnortonrider]

Thanks, 3phase; you've done some good work, here.

Where, did you say for me to go, to download "the legible" version?

[thewiz]

Hey, Scott .... I have the Haynes that has full color schematics. Happy to supply you with it if it could help. Also I'm the owner of a G, so I have a vested interest in this fabulous project

[oldnortonrider]

ok; I have it now. When I saw what was shown when I would pull up the "140K version" link; it looked to be too garbled ~~ couldn't unnerstan' how, if I downloaded it........etc.........and did whut wuz supposed to be done with it, it would no longer be garbled . Hadn't used Windows Paint to be able to do this sorta thing with, before. Figured it, out! I could read the finest print now, with one eye closed.

THIS IS BEAUTIFUL. In the Clymer manual, FYI, it shows that the schematic for the 80G and the 81H is the same~~your schematic is good for both; minor lighting variations in Clymer's schematic(s) for the Standard and Special. So, for anything "serious", one should be able to do fine with your schematic for those two year(s) models.

I've been needing "your" schematic for a long time. This has made my day.

[3Phase]

Originally posted by oldnortonrider
ok; I have it now. When I saw what was shown when I would pull up the "140K version" link; it looked to be too garbled ~~ couldn't unnerstan' how, if I downloaded it........etc.........and did whut wuz supposed to be done with it, it would no longer be garbled . Hadn't used Windows Paint to be able to do this sorta thing with, before. Figured it, out! I could read the finest print now, with one eye closed.

The large version is made to print out in banner mode on four sheets of paper and pin it to a wall or something. My eyesight sucks and I don't like using a magnifying glass or handling paper with greasy hands....

Printing it as a single page it will still be legible (at least on my printer) but you need a magnifying glass and some of the details are lost.

THIS IS BEAUTIFUL. In the Clymer manual, FYI, it shows that the schematic for the 80G and the 81H is the same~~your schematic is good for both; minor lighting variations in Clymer's schematic(s) for the Standard and Special. So, for anything "serious", one should be able to do fine with your schematic for those two year(s) models.

I've been needing "your" schematic for a long time. This has made my day.

Excellent! I'm glad you found it useful as that is why I uploaded it!

I don't have the 1981 schematics but it's good to know they're similar. With hindsight, I probably should have ordered the Yamaha manual for all the years instead of just up to 1980.

I'm out in Arizona right now, visiting friends and just riding and I won't have access to my computer for a while; buddie's wife is giving me the fisheye and wants her computer back.


Regards,

Scott