Constructing a wiring harness...

[andrewraffaele]

Hey guys,


This site has saved my butt more than a few times, this time my bike isn't in any sort of trouble, I just want to make it a bit cleaner...

I'm pretty sure I have a stock wiring harness with many personal (half-ass) fixes done by the previous owner. I'm not running turn-signals and am relying on a kick start these days.

I found the original wiring schematic for the 1978 1100 standard (that's what I ride) thanks to this site, is there a simplified schematic floating out there? I'd like to make the bike a minimalist, no turn signals, kick start, and a tiny battery mounted under the seat so that big ol' 1100 engine looks all alone on the frame...

suggestions?

[crazy steve]

Here's one version... this is off the UK site, so has the 'parking light' (not needed or used on the US bikes)...

http://www.benefiscal.co.uk/forum/in...51818#msg51818

... and another one...

http://www.xs11.com/forum/showthread...+wiring&page=2

Check your local laws for required equipment before you hack everything up, or you might be getting a ticket. Yeah, I know, you see bikes without all that stuff all the time but that doesn't make 'em legal...

'78E original owner

[cywelchjr]

Actually, I believe federal law applies to these bikes in the U.S., and it requires turn signals. State law AFAIK, can add to the federal regs in some particulars, but basically for motor vehicles it's federal law that determines what you must have. It likely would only get you a fixit ticket for turns, but I would NOT recommend removing the wiring for the, as you would have to recreate it if you got a ticket, where if the wiring was still there, you would only need to put the signals back on and get it inspected.

[crazy steve]

Actually, I believe federal law applies to these bikes in the U.S., and it requires turn signals. State law AFAIK, can add to the federal regs in some particulars, but basically for motor vehicles it's federal law that determines what you must have...

Cy is basically correct, but state enforcement varies. The AMA has a reference page on it's website supposedly showing what's 'required' in the different states, but it is not accurate for at least some states, so don't count on that for the straight poop.

And you won't always get a 'fix-it' ticket; get the wrong LEO and it could be expensive...

'78E original owner

[cywelchjr]

Cy is basically correct, but state enforcement varies. The AMA has a reference page on it's website supposedly showing what's 'required' in the different states, but it is not accurate for at least some states, so don't count on that for the straight poop.

And you won't always get a 'fix-it' ticket; get the wrong LEO and it could be expensive...

'78E original owner

Tis true that the wrong LEO could really cost. It's much less likely to cost like that for the turns than for the front brake, which presents a FAR higher likelyhood of a trip to the impound lot for the bike.

[crazy steve]

Tis true that the wrong LEO could really cost...

Three riders I slightly know got stopped because one had a 'blue dot' taillight. By the time the LEO was done writing (blue dot, no rear reflector for #1, no muffs, no turns, no rear reflector for #2, and no rear reflector for #3) they collectively ended up shelling out north of $600; it would around $750 these days.

And they still had to correct the issues... more $$$.

'78E original owner

[DGXSER]

Actually, I believe federal law applies to these bikes in the U.S., and it requires turn signals. State law AFAIK, can add to the federal regs in some particulars, but basically for motor vehicles it's federal law that determines what you must have.

Actually, this is an urban, or not so urban, myth. Federal law dictates what a mfg must do to sell the vehicle or in this case bike. State laws generally indicate the individual drivers requirements to operate the vehicle in their jurisdiction. This was discussed recently here.

[fredintoon]

Hi Andrew,
google "Ken Maxwell simplified chopper wiring diagram"
It's meant for an XS650 but most of it applies.
And DO keep the signals.
Not to save you from a ticket so much as to keep you a bit safer as you ride.
And check out swapping in a Stebel-Nautilus air horn, the 139dB will attract most folks attention even over the noise of their squabbling kids, loud music and someone yakking on their cell phone.

[bgrubb7]

Here is one simplified wiring diagram. I'm planning on using this layout on my bobber. Now this doesn't include lights and signals, which I will definitely be running, but I think those will be fairly straight forward to add.

[bgrubb7]

not trying to threadjack...but what total amperage rating for an ignition switch should I need? I know the stock main fuse is a 30A, but I will be using all LED turns tail/brake and a 35W headlamp. Using my best electrical math, I'm coming up with 3 for the headlight, maybe 2 max for the turns and brake, maybe another 10 for the ignition circuit. Does that sound about right? Should a 20A ignition switch be sufficient?

[cywelchjr]

not trying to threadjack...but what total amperage rating for an ignition switch should I need? I know the stock main fuse is a 30A, but I will be using all LED turns tail/brake and a 35W headlamp. Using my best electrical math, I'm coming up with 3 for the headlight, maybe 2 max for the turns and brake, maybe another 10 for the ignition circuit. Does that sound about right? Should a 20A ignition switch be sufficient?

Typical design theory is to design for 1.5 to 2 times the expected max load. So if you expect 20 amps, the use components designed for 30 to 40 (30 is probably fine). Of course you can't go by the fuse size, as if done properly those are sized the same. So based on the XS 30 amp main fuse, it's expected to have a normal max current of 20 amps approx. So, you want a 30 amp ignition switch as a minimum.