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rewire how to

Discussion in 'The Garage' started by drewpy, Aug 11, 2011.

  1. drewpy

    drewpy Excess twin Top Contributor

    if you are building a harness, don't even include it within the specs.

    Treat each piece of electrical function as a separate entitiy. That was you won't get confused. lay it out over the bike and pre think where you are placing stuff so the wires will reach.

    Ignition system would be the best place to start first and just a simple ignition switch (on/off) will pull the live through to a "distribution centre" and take your live feeds off that.

    earth is easy, I'd have a sep earth(ground) for the electronic ignition if your running one.

    when you are happy with it all, then wrap it, starting from the middle outwards.
     
  2. ksqrly

    ksqrly XS400 Aficionado

    503
    1
    18
    Utah
    Ya I have ran all wires for the charging system, the head unit, and im almost done with the ignition system. Just not quite sure how to bypass the neutral relay. I wanted to figure this out before moving on to the signal system.

    Also did you use bullet connectors for all the connections?

    Posted via Mobile
     
  3. drewpy

    drewpy Excess twin Top Contributor

    yep, Jap bullet connectors 3.5mm I think they are

    just ignore the neutral relay and run the neutral indicator to the negative of a bulb/LED and a permanent positive feed
     
  4. ksqrly

    ksqrly XS400 Aficionado

    503
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    18
    Utah
    Im just going to cut it out. The relay controls the power signal going to the starter relay, so im just going to cut it out and splice. I have done enough research to be fairly confident in this decision. If it doesnt work I will undo the harness and put the relay back in and ground one of the signal wires going to the relay.

    I dont think this will be to difficult because I built my harness in three pieces, so I can easily find the wires I am looking for. In the end it will all be shrink wrapped into one unit.
     
  5. drewpy

    drewpy Excess twin Top Contributor

    cool, sounds like a plan.

    the only relays i have were for the horn and headlamp as I had micro switches on the handlebars.
     
  6. ksqrly

    ksqrly XS400 Aficionado

    503
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    18
    Utah
    Did you ground to the triple tree? I think that is what I am seeing.
     
  7. drewpy

    drewpy Excess twin Top Contributor

    no ran an earth within the loom, thought it more reliable and reduces the clutter at the exposed front
     
  8. ksqrly

    ksqrly XS400 Aficionado

    503
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    18
    Utah
    What is that black wire that is bolted to the tree?
     
  9. drewpy

    drewpy Excess twin Top Contributor

    sorry I see it now, had to go back to remind myself.

    you're right, i did earth the lamps there. the reasoning was they draw the most amps and I wanted a chunky but neat look
     
  10. ksqrly

    ksqrly XS400 Aficionado

    503
    1
    18
    Utah
    Ok cool, I thought my eyes might be playing a trick on me.
     
  11. Pork Chop

    Pork Chop XS400 Junkie

    Can anyone help with this - is there a special sequence for the 3 white wires that go from the alternator to the rectifier or doesn't it matter which wires go where in the connector?
     
  12. drewpy

    drewpy Excess twin Top Contributor

    no sequence, they all come from separate windings which are exactly the same as each other
     
  13. Pork Chop

    Pork Chop XS400 Junkie

    Thanks Drewpy and Ksqrly.
    XS400 electrics are all black magic and dark arts to me. Would it help if I painted a pentagram in chicken blood around the bike when I do the wiring?:devil: :laugh:
     
    Timothy Kelly likes this.
  14. camalot400

    camalot400 XS400 Enthusiast

    hi where did this diagram come from? i really need this as i get to know my bike! iv just been taking things off with no way to put it back on. haha
     
  15. Kristina

    Kristina XS400 Member

    Thank you for this! I am rewiring my 1980 xs400g and creating the layout for the wiring loom is brilliant. I am very new at this and I do not exaggerate when I say this bike is a beautiful mess. Space monkeys took to the wiring amongst other areas.

    I started my layout a few days ago and am almost done sketching in the components. Oddly enough Drewpy, figuring out that you designed your electrical lay out to fit your mod, it's really helped me start to learn and know my bike. I can't just blindly follow this, I have to actually study what you did and then see how it applies to mine.

    Cheers!
    Kristina
     
  16. darrin1

    darrin1 XS400 Member

    working on this low and slow.
     

    Attached Files:

  17. trzcina2

    trzcina2 XS400 Enthusiast

    88
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    8
    Poland
    Hi,

    I'm total newbie here and i'm having troubles with measuring thickness for my cables. After some time i understand rewiring diagrams... but choosing right cable is still nightmare... :)

    I know drewpy posted formula for measuring right thickness but... i have no idea from where i should take those variables in equasion....

    How should i know right voltage and watts for lets say kill swich or headlight swich?

    Someone please help :)

    Cheers!
     
  18. Scorpio1963

    Scorpio1963 XS400 Guru Top Contributor

    To ask a stupid question what is the difference between an earth and a ground wire
     
  19. Sesty

    Sesty H.E. Pennypacker

    different word for the same thing
     
  20. drewpy

    drewpy Excess twin Top Contributor

    its the end "user" that determines the cable needed. running 35amp lamps for instance, you need to get the right cable, then back track to switches to ensure they can take the current so they don't burn out.

    hope that makes sense
     

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