Isnt there an 'abbreviated' wiring diagram out there?

Hi!

I may be wrong, but didnt someone have a bare minimum wiring diagram out there for the XJ.....specifically the 650...but one that would work???

I want to get rid of some of the superfluous wiring I 'THINK' Im seeing on mine....

Any help is appreciated.

 

Which "superfluous" electrical components do you want to remove?

Turn signals?
Instrument cluster?

Brake lights and headlight are pretty much required, unless you will only be track racing.

You could save a decent amount of weight by removing the starter and its solenoid, but you'd have to push start...

The only other theoretically optional stuff I can think of are the run/start, side stand, and clutch safeties, which could be jumpered over...

What's the goal here?

 

OK, so that's no turn signals, no instrument cluster (or at least no lights in it), and no side stand or clutch safeties.

You could even simplify things a bit further by mounting a centrifugal or vacuum advance plate under the timing cover and switching to points instead of the TCI module. That would also save a good four to six feet of wire.

EDIT--------------------------

Oops, this is also no horn, which is illegal in at least some states.

So either put the horn back on or go all the way to a racing bike by removing the headlight, taillight, and brake light. If you do that, you should be able to get by with a smaller battery, which will save weight as well.

 

Thanks Gamuru! Thats the one I was thinking of....I bet its probably posted somewhere obvious....

And SQLGuy

SUPERFLUOUS from Merriam-Webster.
1 a: exceeding what is sufficient or necessary : extra b: not needed : unnecessary

And as I stated, I was asking about wiring, not components. I understand its not an overly ambitious project, but it was an honest question.

 

I understand the meaning of superfluous, but, as there isn't any wiring that's just added for decoration. Removal of wiring is going to go hand-in-hand with removal of the component(s) to which the wiring is connected.

Which devices, and therefore wiring, are superfluous depends on your goal. That's why I asked.

If your goal is a simplified, but still street-legal, bike, then Gamuru's diagram goes a bit too far, since you will need the horn.

If your goal is to get an XJ engine running with the absolute minimum of original external parts, then this diagram doesn't go far enough.

You seem to be saying that your goal is simply to remove unneeded wiring. If that's the case, then you're already done, because all of the factory wiring is functional in connecting all the stuff that's stock on the bike. There's no "extra" wiring like there might be in a car to allow for easier installation of optional accessories.

 

The reason I asked is after tracing 2 wires that were connected to nothing in my headlight bucket to the other end of my wiring harness and were connected to nothing on the other end, I got to wondering.

I remembered awhile back seeing a thread on a similar idea and after not finding it decided to ask. It was Gamuru's diagram I was thinking of.

I thought instead of trying to reinvent the left handed spanner, that I would try to find it and if needs be, do what I need to do to it to convert it to righthanded use.

End all is, I got what I asked for and can from there adapt it to my needs...those being getting rid of 30 year old wiring and making the bike with hopefully a couple less headaches. Besides if I do the wiring, it sure makes it easier to trouble shoot faults if they arise...

 

I see.

You've got my curiosity piqued... did you find out what those two wires were originally meant for? Were they from something a PO had removed, or were they really "extra" wires?

As far as adapting Gamuru's diagram - I still don't understand your goal. If you plan to keep all the things like the side stand relay and turn signals, then the factory wiring diagram should be much closer to what you need.

 

The two wires Im not sure what they were for, looked like a factory....*plug* for lack of a better word yet on each end.

I will probably end up with the same thing as the factory wiring harness in the end, but it will be new wiring and maybe not quite so clumped together...not sure what will happen with it yet ACCEPT NO MORE SPIDERS NESTS!!!!

Ill get pictures of them when I get a new camera, snow didnt agree with mine, at least laying in it for 2 days having fallen out of my pocket.....

 

I used this wiring diagram and its on the money. Im in the process of updating it to include the horn and turn signals with the self cancelling unit. Ill post when Im finished (and verified it works)

 

Hey cool! Thanks Lou!

 

My headlight bucket has the same "extra" wiring. As far as I can tell, the wiring is probably same as another bike or options that might have been added to the bikes when they hit the streets. extra light? extra something.. or just ment to fit more then one bike/style. Aswell, one of the plugs might have been a diagnostic plug in to help trouble shoot or test in factory?

 

Believe it or not, if you took off your harness and wired it like this diagram you would not believe how much less wire there would be on the bike. I wish I had this diagram when I rewired mine. I just started with an original diagram and highlighted everything I knew needed to stay. I didn't want all the sensors such as clutch, sidestand, neutral, oil, exc. There are extra relays for all of that stuff, and when you put an aftermarket head light on, and a key start on the side like I did, you don't want do deal with all this stuff. Mine is wired a little differently than this. because of the key switch. I do have a horn also. Which works by pusing in the key on the electric choke boat switch I bought.

 

In reading all these posts, I find its nessesary to say the reason we make these simple custom harnesses is one; as riders and customizers we dont need various features to tell us when we should or should not start our bike; and the most important reason, that we can look at every wire in our harness and say, "this goes here, and this is why it is there". Designing and building the most elementary harness for our needs lets us do just this; it includes our electrical system (which in many cases is the one thing we dont understand) with the rest of our blood sweat and tears build. Just my $.02, Lou

 

Quick update....my camera is alive! Guess it just needed to dry out and have a good charge on the batteries!!! Yay! I can use the money I saved on the bike!!

 

my ignitor unit (CDI Box) has a black/blue wire that goes to the sidestand relay that I am eliminating. It is the only redundant wire I have. Can I just clip it or do I need to ground it or something?

 

What kind of bike do you have?

 

nevermind, found out the answer on chopperfix.com...i just punched the pin out of the harness connector.

 

How hard would this actually be?

 

it is a joke...you aren't saving that much at all