Color XS1100G USA Schematic

[fredintoon]

Fred: Unraveling component layout and making a legible schematic for each one was something I started to do but I gave it up as an exercise in futility because the equivalent circuit schematics in the Yamaha manual(s) are better for troubleshooting.
The mysterious black boxes potted in epoxy have to be destroyed to see what's inside of them.

Hi Scott,
thanks for your efforts in that direction even if you did give up.
But all I wanted was to be able to find where the mystery modules were physically located, what their outsides looked like, what color wires connected them and if the bike would still run if I tossed them.
My BSA 250 only needs 9 wires to run, fer chrissake! (OK, 13 if you want signals) No effin' way an XS11 should need to use a harness as thick as your wang, eh?

[3Phase]

Fred: Got it! I can probably do that!

Jamie: I'm not Pete but after I get my '79 Special running (or not...) I plan to make a color schematic for it, then make one for my '79 Standard.

I do still have a complete XJ wiring harness and most of the electrical parts so I can make a color schematic for the XJ. It's not high on my list because the bike itself is toast and had to be cut up into little pieces to salvage the few good parts that survived the accident.

[cywelchjr]

Fred: Got it! I can probably do that!

Jamie: I'm not Pete but after I get my '79 Special running (or not...) I plan to make a color schematic for it, then make one for my '79 Standard.

I do still have a complete XJ wiring harness and most of the electrical parts so I can make a color schematic for the XJ. It's not high on my list because the bike itself is toast and had to be cut up into little pieces to salvage the few good parts that survived the accident.

The only issue is Fred has an SG which while similar to the G is not the same, and in some cases very different as far as component placement from the G.

[cywelchjr]

Hi Scott,
thanks for your efforts in that direction even if you did give up.
But all I wanted was to be able to find where the mystery modules were physically located, what their outsides looked like, what color wires connected them and if the bike would still run if I tossed them.
My BSA 250 only needs 9 wires to run, fer chrissake! (OK, 13 if you want signals) No effin' way an XS11 should need to use a harness as thick as your wang, eh?

I don't know how many "mystery" modules your bike has, but I think mine has something like 6 modules or something like that? And as long as they work, there are only 1 or 2 I don't want to keep the functionality of. I'll name them here, if you know of others lets chime in, collectively maybe we can get this pulled together pretty quickly. I believe I can document the position and wire colors of all the ones I know of this weekend.

1. Ignition module
2. Voltage Regulator/Rectifier
3. Turn Signal Cancel Unit
4. RLU
5. Headlight Relay
6. Tip Over Switch
7. Emergency Flasher
8. Turn Signal Flasher

Those are all the "black boxes" I can come up with, and the only one I can see that is not pretty much critical is the turn signal cancel unit. I personally see the RLU as pretty critical unless you have done and HID mod so as to keep from not having a headlight (oh, the headlight relay is rather non-critical really). I really think the size of the harness is more inefficiency in design, too much wire running back and forth instead of keeping thing centralized, with too much desire to have everything inside the headlight bucket, meaning everything had to run up to the front and then back, so likely twice as much wire as needed to do the job. But frankly that old bike didn't have 1/2 the functions the XS does, and that contributes to the size of the harness.

I've got to get into the wiring to troubleshoot my auto cancel unit this weekend anyways, so while I'm in there, I'll document where each of these black boxes is and the wire colors, and where I can, if they can be removed (and many of them can IF you are willing to give up what they do, even the RLU, and I can see the tipover switch not being of much use to a sidecar rig, and you can simply unplug it and remove it with no adverse affects).

[bikerphil]

There is one more mystery module if you have a 79 Special, it's the Light Checker Unit. It will turn on your oil light if your rear tail light is burned out. If you don't know about this, you'd swear you lost all oil pressure.

[3Phase]

Pete: I don't have a Euro/Aussie harness and switchgear to work with and I don't entirely trust the schematics I've seen so I can't help much with the Pass switch in the headlight circuit and the relay on those models. It seems simple enough but all too often the devil is in the details.

Fred: Your '80SG isn't all that different from the '80G except for some minor differences in the gauges, indicators, and warning lights. I can do what you want if Cy can't get to it.

Cy: If you can make a blackbox layout then I can put my bike back together before summer is over!

Phil: That's a good point about the '79SF light check module. It seems to have failed on my project bike because when it's plugged in the Oil light won't go out after the engine starts but it does if I unplug the module. I'm going to need to dig into it to see if it's a bad bulb, flaky wiring, or the module and I am so hoping for a bad bulb or flaky wiring.

[bikerphil]

Scott, I'd bet on flaky wiring. Mine had a short in the wiring where it comes out of the LC module itself. I just twisted the pigtail near the module and it corrected itself. It's been good for 5 years now that way.

[fredintoon]

- - - Fred: Your '80SG isn't all that different from the '80G except for some minor differences in the gauges, indicators, and warning lights. I can do what you want if Cy can't get to it. - - -

Hi Guys,
thanks for the generous offer but I was just sniveling and moaning about the complexity of it all. Me and my sidecutters already got it all fixed up OK so please don't make a whole lot of effort just on my behalf.

[3Phase]

Phil, now that I'm back from a week of fun in the sun I need to buckle down and get back to work. It's possible the light checker module/wires are bad but they looked okay when I pulled the module so I'm hoping it was just a missing ground.

Almost the entire rear fender was made out of rust and even the rust was rusted. I ran a utility knife around the outer edge of the fender and all of the chrome peeled up and off in one solid sheet, like peeling off a giant chrome sticker. It took almost a week of electrolysis to completely clean the fender and the tail light housing and there is not much metal left at all where the tail light used to mount on the fender. The turn signal mounts on the frame are pretty bad, too, so I may have to cut them off and make a bobber. Roo's bike was a blast to ride so it's not all bad.

[Jamie]

Fred: Got it! I can probably do that!

Jamie: I'm not Pete but after I get my '79 Special running (or not...) I plan to make a color schematic for it, then make one for my '79 Standard.

I do still have a complete XJ wiring harness and most of the electrical parts so I can make a color schematic for the XJ. It's not high on my list because the bike itself is toast and had to be cut up into little pieces to salvage the few good parts that survived the accident.

Sorry for calling you Pete. If you can, I would gladly pay you for your troubles to come up with the "color XJ" wiring schematic. Heck, I might even have some parts you may need or can use on your builds. Please, please let me know if I can help or assist in any way.

Thanks again
Jamie

[3Phase]

Jamie: I don't do this for money, it's only a hobby (only a hobby... only a hobby...). If I can I'll make an XJ schematic.

Hi Guys,
thanks for the generous offer but I was just sniveling and moaning about the complexity of it all. Me and my sidecutters already got it all fixed up OK so please don't make a whole lot of effort just on my behalf.

Fred, I've seen enough detail in the pictures of your Flying Pumpkin that, after I get my project bike running, I can probably make a schematic for you complete with the battery and sidecar connections: almost no effort at all!

[oakback]

Anyone have a copy of this? Either it's not showing up for me, or it's no longer there, I'm not sure.

[3Phase]

I have a copy, Oakback, send me a PM with a valid email address and I'll give it to you.

I just closed the account today where the file was hosted but a few people have it stashed in various names and image formats too.

.

[3Phase]

Moving Day

My color schematics have been moved to Dropbox.

Both full size versions of the schematics -- GIF and PNG -- are 1536 x 2048.
The full size schematics can be printed out on four sheets of paper in Landscape mode, then taped together.

The small webgraphic versions are only 480 x 640 and were made for dial-up users reading this post.
Please don't strain your eyes, they really don't zoom well.

Left-click either link or image to download the full size 1536 x 2048 schematic
Right-click SaveAs will get the smaller 480 x 640 web display copy.


Full Size XS11G_US GIF | 1536 x 2048 | 146K / XS11G_US webgif 480 x 640 | 53K



Full Size XS11G_US PNG | 1536 x 2048 | 122K / webpng | 480 x 640 | 50K



Enjoy!

.

[3Phase]

My old inkjet printer died so today my faithful protégé and I figured out how to print another multi-page schematic with the new laser printer.
I think she was dogging me because I had to do everything while she just looked and licked her chops.




The correct tool turned out to be good old MS Paint with the image Zoom at 100%.
File | Print | Page Setup
Paper size is Letter
Margins are all 0.166" (won't allow a margin of zero)
Orientation is Landscape
Scaling is 2 x 2
Uses four sheets of 8 1/2" x 11" paper




The schematic 146k