wiring loom

hi guys picked up my maxim engine and wiring loom today just wondering if anyone had any help with the loom if i had a few question? i need to know what components should be attached tpo the loom for its year, its a 1985 as far as i know, i have the cdi, flasher relay, solenoid, clocks ignition barrel i think,rectifier,coils and horn anyone any ideas roughly what i could be missing?? thanks

 

bump on this guys im really stuck heres also there is three wires with connector blocks coming from the left side of engine, i need to know what or where they go if possible thanks?

 

Really for something this involved you need to be looking at springing a few quid for a manual, the right one for whatever bike you have (400twin/400four/550/650/700/750/900????) then you can see the wiring diagrams & be able to test components.

Can't really say much more than that without knowing specifics sorry

 

ok i have a picture here on the pc of the two casings that have wires coming out from them but i cant post the pic for some reason, it would prob make more sense if ya seen what i was on about even.....its a maxim 600 or 650 not 100%

 

Should have the capacity cast into the barrels low on the front near where they join to the cases IIRC

Probably you have one plug with black/orange/grey that'd be further forward & is the ignition pickups, the other ones I can think of would be 3 white wires and a brown and a green & they'll be the alternator...

The black/orange/grey plug goes to the TCI (what you called the CDI, it's really Transistor Controlled Ignition on these )

The others from the alternator would go to the reg/reg unit via multiplugs with matching colour wires

 

ok that makes sense alright dude, i just assumed cdi my bad, def three white wires anyway and i think the other two are brown and green, (there fairly dirty) seen as you know your stuff, i have hand controls here i ended getting a few diff ones with it i dont think i have the right ones though, how many connectors are on each one? (left and right) also on the wiring loom itself what is the bright green connectior for? its a female connector.....

 

Ummm, I'm just sat looking at a sheaf of wiring diagrams lol :lol:

As far as the switchgear goes, it depends on if it's UK or US spec I think, US spec only have kill switch & start button on the right, confusingly though both right switchgears only have one plug. UK main loom would have 6 wires and US loom would only have 3 wires in a 6 pin plug, suppose if you can identify which is the plug on the main loom you can see then if you have the correct right switchgear.

US left switchgear has 2 plugs, 3 pin & 6 pin/ UK has 2 6 pin plugs but one of these only has 4 wires in.

This is just going from the diagrams so not sure of plug colours but should be able to find matching ones on the loom towards the headlamp plug/front end if the switches are correct.

IIRC the bright green connector would be to do with the safety circuit (sidestand switch/clutch switch etc) but don't quote me on that haha

 

ok well i have one left hand control that connect to the loom but could be in wrong place i suppose, i cant understand them wiring diagrams at all that i find online need proper ones, also if i was to just see if the engine would turn over as is now without the loom, im not looking for it to start but just to see if im in a position to carry on is there a way of getting the starter to run? just from a battery? would all the wires be colour coded in the loom to there correct switches or would some be different?

 

If you don't know the history/health of the engine, the best option would be to take the spark plugs out, remove the ignition cover if fitted (the round cover with yamaha on it (and possibly YICS sticker) left end of the crank, should contain the ignition pickups with black/orange/grey sprouting forth) and turn the engine slowly by hand with a spanner on the square nut.

Be careful not to whack the pickups with the spanner if they're fitted...

Better than spinning it on the starter if there's bad stuff inside.

What plugs are on the left control, how many pins in each? If the number and colour of the wires matches the ones its plugged into on the main loom you should be right.

 

on the left control one connector with for wires all wires match colors on loom so should be grand also on it, are two bullet connectors, pink one (female) and a black one (male) and the block connector for headlight....probably the right idea with turning over the engine even though it has def been dry stored for however long it was sitting up, i have a little rectangle very thin piece on the loom its plugged inb but i dont think the right place, *wires dont match up) but i dont know what it is any ideas? its inch and a half long by an inch wide but only about 5-10 mm thick......

 

Aha, I deduce that you have a hacked US spec left switch. The 4 wires are in a T shape right? then the 2 empty spaces would have been the pink & the black originaly.

The 3 pin with yellow, yellow/red and green is not the actual plug for the bulb, that should be elsewhere on the loom (normally black plug with yellow, green, black wires). The 3 pin switchgear plug should have a corresponding plug into the loom

Unidentified object could be diode block (5 wires, 2x white, 2x brown, 1 blue/white). A photo of that would help if you can get it. (photobucket is the best hosting site IMO, you upload pics there & then copy/paste the link

EDIT-: By the way, I'm starting to get a little tired now so may get confused easier lol.

 

i have the four wires connected to corresponding wires on the loom, the plug for bulb has a yellow, green and a black wire in it like a t shape and a yellow and black bullet connector coming from it also< maybe for parking bulb? these are coming from the same control but are seperate from connector block i dont have any spare pins or anything as you say,.....i could be picking you up wrong of course.....

 

Right, just so I'm not getting my wires crossed here (see I even make my own puns lol), what exactly are the plugs on the left switchgear. Regardless of where any wires are for now, just the plastic plug bits... Do you have a 6 slot plug & a 3 slot plug coming from the switch, or do you have two 6 slot plugs?

 

Also, I'm reaching the limits of my diagrams & knowledge at this point. None of my diags show a yellow plus black for a parking light bulb. My US spec ones don't have a parking light shown & my UK ones have blue & black wires to it...

I suppose it's possible someone's added it in later or rewired with diff colours but I'm getting to the point where I'd need to at least see photos if not look at it in front of me to get much further lol

Maybe something'll come to mind overnight as I sleep (has been known to!) or perhaps someone else will chime in to fill in the gaps... In the meantime I'd suggest getting some way of hosting pics sorted & having a play with the engine to see that it's free to turn & gears seem to select etc...

EDIT-: Oh, while I think of it, what do you have for right hand switchgear at the moment? Could do with finding the plug for that on the loom as that may help identifying for sure what country's loom we're dealing with...

 

photos

have updated this with pics of where im stuck on the loom all description of wires is in the comment underneath pictures thanks

 

Righty ho then... Just added the pics as photobucket's being slow today & also everyone can see them now I'll go through the post editing in any comments shortly so check back over it & I'll add them in blue text... I'll do my best & invite anyone else to get involved too, but TBH the loom looks pretty hacked up & it may be worth getting another better loom that you know what spec it is & know the colours are right... Is there a sticker anywhere on the loom with a chassis number or model code on it?

but I see a yellow there too. Could do with lining things up flat with the wires spread out untangled a bit if possible... what colours does it plug into on the loom? It does look like a diode pack :?

This one sounds like a US 750 max but some wire colours don't fit my diagrams, pic of the 6 pin's wires please?

Can't find any connector with that combo in my diagrams

Likely to be front brake light switch

US (Maxim) left switchgear, diagrams weren't great here but would say the bullet connectors go together if they seem to "fit" how the wiring would be routed if fitted to the bike

My diagrams don't show a black/white going to the regulator :? they do have a white wire from the reg/rec to the diode plug though so maybe that's an error in the diagrams?

Likely to be sidestand switch

May not be XJ, none of my diagrams show that plug combo. What are the wire colours?

 

OK well, in the post above I've gone as far as the pics & diagrams will let me for now. Unless anyone else wants to chime in with additions/corrections to my comments?

Personally I'd search for a decent loom, or make up the minimum wiring setup from one of the diagrams available around here. (maybe best option if you're building a trike not using the XJ frame. What exactly is the project?)

If you really want to persevere with the loom you have & nobody you know locally can go through it for you, I'd be happy to take a look if you sent the lot to me, might take a while to work through it & postage may make getting a known good loom a better option but let me know if you want to send it over let me know & I'll PM my address.

I'd have a sort through it with multimeter & test lamps, get any bodges/damage/loose wires sorted, connect up the switchgear & label it all up for you. No charge apart from postage & any parts it may need, I just like playing with electrics lol.

 

ok so in the post about the spare connector with a black and white going to reg/rec? i meant to say it is going back to the tci! and on the diode i have included a new pic and i left out the yellow wire before, the only code on the loom was 1FG-not 100% on the 1FG but 99% (the writing is a bit faded) ive included new comments anyway to explain ab it better for ya to check out please... thanks

 

Right, 1FG tallies to a 1985 49 state US spec 700 maxim according to Chacal's lists

Might explain some differences, my diagrams don't cover 700 models. The majority should be very similar but there will be variations. If you can find one, at least you know that's the wiring diagram you need...

Will have another looky see

 

ok so that means im dealing with a 700 after all? hmm that explains why there would be difference alright im finding it so hard to find manuals or anything online here!!

 

Have you looked at the engine to confirm what you have? Should have the capacity on the front of the barrels, central near the bottom.

How much of a bike do you actually have & are you building your own frame or using the original?

If you're going for a largely custom build you may be best off getting a custom loom too, even without diagrams a good electrician will be able to knock up a suitable loom.

 

thanks again for looking at all that for me man really appreciate it!! and no i didnt check it, havent got it here now to check either stored somewhere else i do know that the code on the loom matches the code on the engine....i have the full engine and whatever bit of the wiring loom,i have the shaft from it and exhaust system all that,im supposed to be picking up a frame soon well goin to look at it anyway a 77 cb 750 rolling chassis, so that will be my basis, a custom loom would be better alright but thats why i wanted to work out what everything was, biggest problem i can see is the fuses are up in the closk system, so could be a pain enough ill prob just use original clocks for handiness!

 

Ahh yes, the 700 had blade fuses as standard didn't it? that's a blessing in disguise, most others came with the old disintegrating glass fusebox! If the engine's got 1FG code then it'll be an '85 49state XJ700 same as loom then. Should be able to get away with the stock loom in the CB chassis I suppose as it won't be that huge compared to if you built a custom trike chassis with the engine about 3 feet from the bars lol

Did you get the carbs with it? They take the same 33mm carbs that my E-II uses & they're a *pain* to get hold of (I'm still searching, as per the wanted ad in my signature lol, found maybe a couple of sets in the US & Canada but shipping is gonna be a killer even if I can get them!

The more common 32mm can be made to work (that's what I'm making do with now) but if you have the proper 33's then bonus!

 

carbs are on it too yea everything was there really as the guy that had it only cut up the frame to use the front end for a vw trike, so i kept pestering to get them bits off him too as he would never use them! i got my rear diff and drives for the back of trike from him too so all in all so far im out nothing but my time on here

 

Cool, be careful rebuilding those HSC33's if they are original, they're rocking horse shite!

Hope you're going to start a build thread in the XJ modifications area? I wanna see what happens with this, not seen an XJ based trike on here yet...

 

oh it will be someone with a bit more experience going near the carbs id say, id hatre to mess them up! and id say it would make you cry to know that there was a perfectly good set ruined lol oh ill throw up an ould thread once i get the frame and see where i stand then ya know! anyway thanks very much once again man i really do appreciate it!!

 

In what way were they ruined? And where are they? I might want them for spare parts still lol

They're not that bad as long as you don't rush, main issue is breaking off the float pillars if the pin is stuck.

 

nah wat i meant was IF i ruined them it would kill you to know that a newbie f***ed them up when ya could of had them lol ah ill leave it to the more experienced anyway better off, at least i knda know where i am headed with this project now anyway once i can get a diagram!!

 

lol misread it, can tell I'm past my bedtime 8O

most on here will tell you the only person who will be prepared to do a proper job of cleaning your carbs as thoroughly as they need to be is yourself, as long as you're gentle with the float pillars & use proper fitting screwdrivers you're generally good.

This is a good thread for carb cleaning, very very long post but worth reading all the same http://xjbikes.com/Forums/viewtopic/t=14692.html

 

hey guys found this link on ebay for a wiring harness, im not looking to buy but i was wondering what the components are in the last pic as i havent got thesen (i dont think) ebay link

 

any idea lads??

 

broken link
Did you mean this listing?
YAMAHA-MAXIM-XJ700N-1985-COMPLETE-WIRING-HARNESS

The last pic looks like the mounting plate for the TCI.

 

yep thats the one i was wondering what the blue connector block is?

 

Too long didnt read, just don't plug the connector for the headlight relay into the TCI.

Don't ask me how I know either. :lol:

 

Sorry missed the post, the thing with blue connector is a relay. For what I don't know, someone with 700 experience will know.