Rewiring ignition

[Buckb]

For Ken and All the experts! I am customizing another 79 XS1100. Has anyone had any experience in rewiring thses bikes? My question is, what can I eliminate in that enormous array of wiring and gadgets and get down to the basic necessities for the thing to run? I'm eliminating all teh factory lighting for starters but concerned more about the ignition system. Thanks to any and all, Buck - Atlanta

[TopCatGr58]

Hey there Buckb,

Find RainbowShooter,

He rewired his XS completely(he's an electrician), he also found a problem with the schematic, but he hasn't posted the plans or details on how/what he did to correct this!? He could probably give you some good advice on what could be left off!

Like you said, you got rid of the lights. You'll need the CDI and its related items, and the charging system. The tach would be nice to keep. The ignition key circuit, or something similar to prevent/deter theft. Oil sensor, fuel sensor. Do you have a wiring diagram?? But if it's going to be for the street, you're going to need the lights, brakelights, horns and such!

Good Luck.
T.C.

[Ken Talbot]

Hmm, I think you might be able to get away with no more than the following:

• battery
• charging circuit
• ignition circuit
• starter circuit
• brake light
• headlight and tail light
• horn

Forget about:

• tach
• fuel gauge
• neutral light
• instrument lights
• emergency stop switch
• running lights
• signal lights
• oil pressure
• tip over kill switch
• four way flashers
• electric vest plug-in and coffee warmer

[Buckb]

Thanks

Thanks for the help. this is a street bike. The reason I want to eliminate the excess wiring is for space.

We have chopped this bike, lowered it, shortened it, changed the rake to 34 degrees. We cut out the double tubed backbone and replaced it with a single to accomodate a 5 gal fatbob tank.

We also changed the fenders to composite streetsweepers and chromed the wheels, swing arm and final drive. So we are looking for this to be a nice chopper for my wife when we complete it(hopefully before Bike Week in May in Myrtle Beach.

Thanks again! Buck Benton

[MartyA]

Wow!
Photos, need photos!!

[rainbowshooter]

OK, I finally got back to the rewire. I am putting the schematic into Autocad format this week, as long as everything stays non-hectic. I will have the original, the minimum, and what I have on my bike. If anyone needs them in a bmp or jpg just give me a shout. I re-did my connectors to reflect less circuits, cancel unit and the like, also the fuse box. I still need to make a pre-assmbled harness and fuse block for a few guys that had asked. Good luck on the mods, and like Marty said it should look awesome in some pictures!

[Bill]

Make this a Tech Tip!

Harley Dave wrote:

I finally got back to the rewire. I am putting the schematic into Autocad format this week, as long as everything stays non-hectic. I will have the original, the minimum, and what I have on my bike. If anyone needs them in a bmp or jpg just give me a shout. I re-did my connectors to reflect less circuits, cancel unit and the like, also the fuse box.

That would make a great addition to the tech tips under Modifications/Battery and Electrical! A jpeg of the schematic, a description of your connectors and any other related wisdom would be great!

Ken Talbot, Mike Hart, or Gary "sixtysix" Granger are moderators on that forum and could post it there.

XSively,

[Buckb]

Thanks

Thanks. will put photos up as soon as I finish this project. I posted pics of our other bikes but they have not been put in here yet. Thanks to everyone for the assist!! Buck