Wiring harness 78E

[Crazcnuk]

I need a wiring harness for my 78E. Are there any other years/models that will also fit?

[Rasputin]

Hey Keith.
I have a 78E parts bike here with most of the wiring harness intact. The only bits I seem to be missing is around the fuse block it has been monkeyed with. You are more than welcome to come down and get it if you like. Later Doug

[Crazcnuk]

Mine has the upgraded fusebox. Don't think I will be headed your way anytime soon though.

[dbeardslee]

Can't you transplant the harness from the junkyard dog? There might be some minor differences - two horns vs. one, and the on/off switch for the headlight come to mind. Might be some difference in the type of connectors used too, but you should be able to transplant them as well. You could always lay it out over the top of the frame before weaving it into position, and compare it to the one that's on it. JAT

[Crazcnuk]

I'm not sure, hence the thread.

The 78 doesn't have the on/off headlight switch, anyway, but ALL the plugs from the solonoid back are melted to nothing. The big white one was cut clean in half with a soft chewy center.

I know some of th eplugs are different between the 79 special, and the 78, but I think the 78 and 80 are more similar.

[Eveready1100]

Mate, if it helps, I've done a harness change on my SF Special using the loom from a '78E. Main differences were in the headlight shell where the connectors were different. Avoided headache by just fitting the E model gauge cluster and all was straight forward after that.

[dbeardslee]

I've got a '79F and my brother has an '80G, and the harnesses are very similar. Going from a special harness to a standard could be problematic as I've noticed differences in the connectors, as well as their location. With the TCI in a different place on the specials the wires may not be long enough to reach the more rearward location of the standard's TCI.

If the 78 harness got hot enough to melt that many connectors, you're probably right to replace it - no telling what the heat did to the insulation on the wires in obscure locations.

On mine I went through the harness, and replaced almost every crimp on connector and connector housing. That paid big dividends in terms of the voltage readings at the TCI - I recovered a full volt by replacing connectors, and that was after I had cleaned them. I'm pretty sure Geezer sells all the stuff necessary to redo connections - including a really nice compound double crimper for not too many $'s. Might be helpful if you need to make some adjustments to the 80g harness for it to work in the '78. JAT

[Crazcnuk]

All the other harnesses, except 78, have the same issue with the placement of the TCI.

My harness has no plastic at all from the front of the rear fender back. Also the blue running light wire is melted, I imagine, all the way to the headlight bucket.

The wires going to the headlight relay are fried, the red/white and blue think they are the same wire.

[latexeses]

According to the Haynes and the Clymer manual the E & F US models are the same and in the Haynes manual the E & G UK models are the same.

[3Phase]

All the other harnesses, except 78, have the same issue with the placement of the TCI.

Craz,

GarthXS put an '80G harness on his '78E. I think he put the TCI in the seat well over the battery. You can gleep the left handlebar switch and 2-prong flasher off the '80G to use the 4-way flashers on your '78 or just not use that feature.

The '79SF has the Light-Check module that uses the Oil light as a warning light for bad bulbs so it might not work without that module.

[Rasputin]

The 78 doesn't have the on/off headlight switch, anyway,

Hey Craz. I have 2-78E's and both of them have the on/off switch for the headlights. Including the stepsons 79sf I have 5 XS11's here in various stages, so it makes it hard to find the time to strip the harness out and send her up there. I can certainly do that if you want it though. I have not looked it over real good but the bike was running a while back. It's not like I can take pics that would tell you anything. Let me know if you want it and I will find the time to get it out and inspect it better, then let you know. Later.

[Crazcnuk]

Mine is supposed to have the switch but the PO put a later year switch assy on.

I really need a harness. This one is pretty shot. it had other damge before, this kind of finished it.

[Rasputin]

I had actually meant to PM you that last one....couple beers and you know the rest. I am out in the garage right now but the parts bike is in the cold storage in the dark so I cant see sheet till tomorrow. I do also have both halves of the switch...but no kill switch or start button parts, if you want them too. Hopefully tomorrow I can strip it off. Rode three of the bikes tonight, just some stuff like clutch adjustments on one and a fork oil change on another and some switch repairs on the third and I should be good. Anyways i will see what tomoorow brings and see if it looks promising or not for you.

[Crazcnuk]

I have the other parts of the right switch, ie: kill and starter button parts. I am just trying to get this one finished, and each time I get close some other catastrophe happens!

[Crazcnuk]