Harness being placed back into bike. Notice that I used some harness wrap and tie wraps rather then electric tape. Harnesses are not wrapped in electr

Harness being placed back into bike. Notice that I used some harness wrap and tie wraps rather then electric tape. Harnesses are not wrapped in electr

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Harness back in bike. I found it easiest to completely remove the battery holder and disconnect the rear shocks. This gave me more room to route the h

Harness back in bike. I found it easiest to completely remove the battery holder and disconnect the rear shocks. This gave me more room to route the h

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Starter with the new larger gauge wire.

Starter with the new larger gauge wire.

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I had to remove the side cover to reinstall starter.

I had to remove the side cover to reinstall starter.

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Bullet connections with clear heat shrink on them.

Bullet connections with clear heat shrink on them.

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Part of cooked harness

Part of cooked harness

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Inside the Ignition. The harness burned up into the ignition so I had to replace the wires and re solder the connections.

Inside the Ignition. The harness burned up into the ignition so I had to replace the wires and re solder the connections.

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The T50 staples I used as an extraction tool.

The T50 staples I used as an extraction tool.

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The Amp/Tyco sockets I used

The Amp/Tyco sockets I used

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2. Mark each connector with a number to identify it. Mark the board with a line to indicate the branch length. On your schematic, indicate the connect

2. Mark each connector with a number to identify it. Mark the board with a line to indicate the branch length. On your schematic, indicate the connect

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New starter cables. I used some epoxy and mil spec lugs from work.

New starter cables. I used some epoxy and mil spec lugs from work.

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1. Harness. When rebuilding a harness, start by placing the old harness on a board to make a harness jig. Use a few 4 inch nails to mark all the branc

1. Harness. When rebuilding a harness, start by placing the old harness on a board to make a harness jig. Use a few 4 inch nails to mark all the branc

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Schematic used. This was posted on xs400.com a few weeks ago. I had to modify it to work on my bike. The changes were located around the fuse holder a

Schematic used. This was posted on xs400.com a few weeks ago. I had to modify it to work on my bike. The changes were located around the fuse holder a

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gbyamaha

1979 xs400 (xs250) harness rebuild

After my harness caught fire in November, I had to rebuild much of the harness. Here are some pictures from the project. I was able to reuse all the connector shells by replacing the pins/sockets with standard amp/tyco replacements. I used a T50 staple as the extraction tool. The bullet connections were cheap at Princess Auto. I simply used some clear heat shrink to cover their ends. The schematic was posted on this site, but I had to change a few wires around the fuse panel. I started the project on Jan 17 and took the bike for a spin Jan 23rd (burr)
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