XS500 Custom Harness Help

[shoebox5]

My 1977 xs500 was running when I first got it but when I tore into it to simplify the setup I noticed how horrible the wiring was. It was a mess, some wires were only finger twisted together and barely covered with duct tape. After hours of frustration of trying to figure out what goes where... I made the mistake of cutting and tearing everything out and not knowing what I need and don't need. -_- Rookie mistake.

So now I am trying to figure out with basic wiring diagrams what is needed to make my bike run again. I tried wiring everything up to battery and the points but unfortunately I don't know what I'm doing. I've read the "must read" section of this forum and still I don't know what is needed and isn't.

My goal is to have a kick start only, I removed the starter and the starter chain. I only want a brake light, headlight, and for the bike to run... It sounds simple enough and I should be able to figure it out but alas... I am so lost. I will post pics of all the switches, resistors and relays in hopes you guys can tell me what I need and don't.

Thanks for any and all help.

 

[Yamaki]

I have the diagram somewhere, let me see if i can dig it up for you.

My project will be running kick and electric start but i am thinking about making a simplified custom harness myself
so we might be beneficial to each other here

Is your solenoid working?

Do you get Voltage in your coils?

Edit: here it is.

 

[Ichiban Moto]

thank you , this diagram will be helpful. I just bought a XS500

 

[Sonreir]

My goal is to have a kick start only, I removed the starter and the starter chain. I only want a brake light, headlight, and for the bike to run... It sounds simple enough and I should be able to figure it out but alas... I am so lost. I will post pics of all the switches, resistors and relays in hopes you guys can tell me what I need and don't.

You going to want to take this circuit-by-circuit. Trying to tackle everything at once (for someone who is unfamiliar with wiring) is not likely to lead to a successful outcome.

Tools and stuff you're going to need:
*Elecrtrical tape
*Wire cutters
*Wire strippers
*Inline fuse (something like this). Make sure the fuse you're using is 15A or less. 7.5A would be good if you can get it.

Step 1: Get your battery in place on the bike and ensure it is well charged. Connect the battery's negative terminal to the frame and/or engine using the 10 gauge (thick bastard) wire that (hopefully) came with your bike.

Step 2: Hook up the positive terminal of the battery to the fuse (keep the fuse from touching bare metal at this point of you're gonna blow it.

Step 3: Run a wire from the fuse to the red/white wire on the coils (don't leave it connected too long as you will cook the coils and/or drain the battery).

Step 4: Use the kick starter to try to start the bike and assuming you don't have any other issues (carbs, timing, compression, etc) then the bike should start and run. Disconnect the wire from the coils to turn the engine off.

Step 5: Now add the kill switch into the mix. Take the wire you have running to the coils and, instead, connect it to one of the red/white wires on the kill switch (doesn't matter which). Take the other wire on the kill switch and run that to the coils. You still have a path from the battery to the coils, but now you have a switch in between you can use to turn things on and off. Bike should still start and run so long as the kill switch is set to run.

Step 5 though 712: Repeat this process with each system on the bike. Run power from the battery to the component that needs it (head light, tail light, etc) and after verifying it works, expand the circuit to include the switch(s) that control that component.

If you get stuck, let us know and we'll help out.

If you're not sure you're up to the task (even with our help), I can make you a new harness and mail it out. Details in my signature.

 

[smz89]

Hey, I have a XS500 as well. I knew nothing about bikes let alone wiring before. Just had to learn as i go. Thanks to a lot of Sonreir's post i figured it out. This diagram helped me as a lot, but i used two diagrams to incorporate turn signals. And surprisingly it all worked out and the bike runs. I too ran it off of a kick start as from what i have read, the XS500's have a bad starter button. If you have any questions let me know or PM me and i can try to help you out by looking at my bike and giving you wire colour configurations and what not. But Sonreir is the man for electrical work!!!!

And incase you want signals on it for your safety, I attached the other diagram that you can figure out how to add signals. Good luck and I hope it helps you out!

 

[ILoveThumpers]

Step 5 though 712: Repeat this process with each system on the bike...

LOL I wondered how far you were going to take that line of thinking!

-Deek