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HELP!! Wiring issue

Discussion in 'XJ Technical Chat' started by lostboy2, Jan 21, 2011.

  1. lostboy2

    lostboy2 Member

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    I'm new to this forum but I think it is great! I have a 82 xj650. Had a broken tach so I went to replace. Broke the bolts off the headlight so I had to unhook all the wires to get the broken bolts out. Like an idiot I didn't mark all the wires so I am in need of some assistance. I have all the connectors re-connected but I have several other single wires with barrel connectors on them that I can't remember where they connect to. Any help would be greatly appreciated. If you have a picture of the inside of the headlight cluster, that would be great also. Thanks in advance for anybody's help.
     
    lostboy2, Jan 21, 2011
    #1
  2. bigfitz52

    bigfitz52 Well-Known Member Premium Member

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    Most of the "critical" connections are in unique square connectors that you can't mess up.

    GENERALLY speaking, the only single bullet connectors should be the turn signal leads and their grounds; and possibly the horns.

    Green-green; brown-brown, black-black.

    Here's inside a 550 Seca shell; similar but NOT exactly the same (more connections.)

    The unmarked black and brown wired "clumps" toward the right side (in the pic) are the turn signal leads and their ground connectors.

    The "marked" connectors are for the Seca's cluster, you won't have those.

    [​IMG]
     
    bigfitz52, Jan 21, 2011
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  3. cutlass79500

    cutlass79500 Well-Known Member

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    Fitz even the inside of your headlight shell is clean so i guess we can say your bikes are clean inside and out looks good. The later xj viragos and vmaxes have more wires. with the little headlight you have to get them turned just right to get your headlamp on
     
    cutlass79500, Jan 21, 2011
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  4. bigfitz52

    bigfitz52 Well-Known Member Premium Member

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    Thank you.

    Every shell I ever came across on Jap bikes, even PERFECT ones, are rusted to beat the band on the inside. I have one right now that's gorgeous but it's also rusted completely through in spots. Enough to make a growed man cry.

    My standard procedure is to wire-brush/soda blast the inside as clean as possible; paint with "Rust Converter" then sand halfway smooth with 800-grit and spray-paint with Duplicolor low-gloss black engine enamel, as in the pic. I've done probably half a dozen that way, and they stay nice for years. Quick-n-easy, aids in maintenance and promotes reliability (not having all that rust in there.)

    This one was easier, because it came back from the plater nearly rust-free.

    If you're feeling really hinky, fit a set of headlight shell hole grommets (on the big holes for the harnesses) like came on my Nort. Len has them.
     
    bigfitz52, Jan 21, 2011
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