rewire how to

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.
 
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?

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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
 
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.
 
cool, sounds like a plan.

the only relays i have were for the horn and headlamp as I had micro switches on the handlebars.
 
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
 
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?
 
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:
 
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
 
working on this low and slow.
 

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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!
 
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!
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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