XS650 Charging System How to Wire it Up - Continued

[danubbz]

can ANYONE PLZ HELP!!!! i have a 1980 xs650 its my first bike build and ive used every diagram and scamatic i could find but still nothing if ya can plz help my email is danubbz@yahoo.com and it will b greatly appreaciated. and bro great video, its videos like this that keeps bikers goin (real bikers) sorry 15,000$ and 15 miles dont cut it hahahaha! THANK YAW VERY MUCH!!!

[chris1592]

WHY IS MY FUEL LINE NOT TAKING IN MUCH FUEL??? I was running my xs650 today and i noticed my fuel window cone thing kept draining completely out as if i was getting a blockage of fuel somehow. i tried riding it around but its just acting upp...ANYONE please if you can help me with some pointers i would greatly appreciate it.

[dam1en666]

can anyone help?????? im running the points system still and am having problems rewiring. i have the 2 coils running to the condencer/points. when i bench test, it all works fine but when i fit it to the bike and wire it to the points i lose power??? power goes to coils but doesnt come out?? and yes on the bench test i have power in and out of the coils?? could this be the points?? or maybe something else??? any advice would be great cheers.

[jlamond1955]

great bike i have a 81 i just hard tailed , just wanted to know if you lowered your front end , or pushed the forks through the top of the tree ?

[Michiganborn1969]

Did I find the right YouTube channel dedicated to motorcycle repair & maintenance? I found the information in this video precise & detailed but wonder if the application would still be the same for my 1985 Yamaha Maxim XJ700 that's having some issues with idling & MAYBE related to the electrical system. It wants to stall at idle even after warm up. When I use the brakes or turn signals the lights dim & I wonder if they're related or separate issues? Btw the carbs were just rebuilt 5 months ago.

[revmasocistic]

I've got a 75 with seperate rec/reg which is really throwing me off. I pretty much got this bike in a box with nothing wired. Any suggestion?

[01ps]

Hey, thanks for the vid. I am wiring my XS400 bobber and running into some trouble. Is there any way to tell which white wire goes to which terminal on the rectifier, or doe it matter? Mine is not a points system.

[180204]

thank you I am doing the same thing

[dfman107]

I have an 83 model if I understand this I don't use the nylon screws is this right? Great video too!!!

[CObobber]

Any chance changing out a '72 xs650 from the single reg and rectifier to a reg/rec combo (as in your vid) that it might ruin the rotor or stator?

[electricchurch666]

@CObobber - Not likely. Although you are sending ungrounded positive current to the brushes, The rotor and stator are not the kind of items that can "get fried". If your charging system still isnt working, first check to make sure you didnt miss anything, then check your fuse, finally try testing the rotor. I've done this conversion on a number of bikes and havent seen and rotor/stator damage yet. NOTE: xs650 rotors are notoriously sh*tty. Windings get heat damaged over time.

[xs650fanatic]

Great video, thanks for the info. One question, why did you use the nylon screws? why did you unground the brushes? thanks and great job!!

[electricchurch666]

@xs650fanatic gotta convert the old brush/rotor/system to the more modern design. The only rotor/brush/stator difference in the later model TCI bikes was that both brushes are ungrounded.

[smashwizard]

I have a '76 xs650 and am running a reg/rec like yours. I'm also using a pamco electronic ignition and a toggle switch instead of key switch. My question is in regards to the power feed to the brown/black wire. I run a wire straight from the battery to the switch and from the switch to the brown/black wire? Is that wire the feed to the headlight and taillight? Or where do they wire into?

[electricchurch666]

@smashwizard

correct power to switch.

switch to black/brown to power reg/rec.

The down side of using a simple toggle is that generally the toggle only has one lead out. You should add another line to power your headlight and taillight. In fact, you should consider another solution instead of the toggle switch. Toggle switches dont generally last long with outdoor use. Also, if you tie in your lights and reg/rec on the same terminal, you can end up blowing bulbs or get signals interference.

[smashwizard]

@electricchurch666

Alright! I wired it just as you said in the video and it seems to be working fine so far. First setup of 3 that has actually worked. What do you recommend I use instead of a toggle? Regular key ignition? I'd have to find a spot to mount one and then what do I do about wiring the lights? They are wired into the brown wire per another diagram from pamcopete. Seems to be working fine though.

[sean12582]

you are saving my ass i did not want to pay my boy 50 a hour to wire my bike

[electricchurch666]

@sean12582

ROCK-N-ROLL - save the cash - buy some beer.

[sean12582]

@electricchurch666 beer is alot of money when it comes to building bikes, where do i find a rectom thing whats the part num. can i rob one from a junk bike

[TheRockersway]

hm.

[jczooyorkkid]

Awesome video! Great Job.

[skulfuct]

where are those filters from?

[MotoCasa]

I found the screws and have many. If anyone needs some write me direct and I will see if I can get them to you.

[MotoCasa]

any tips on where to find the 4m screws?

great vid

[jaredford002]

@MotoCasa Home depot has them $.50 for two

[MotoCasa]

@jaredford002 not at the 3 Home Depots in my area. They do have SAE screws that look close but not metrics in this size. I had to order them online, 100 piece minimum order.

[brett762]

Nice video, great resource. I have a 79 engine that I'll be wiring up soon. Off of my rotor/stator assembly I have a couple of wires that are not mentioned in your video; blue and yellow. Are these not utilized? Thanks

[MotoCasa]

@brett762 The blue wire just loops through the harness and goes to the nuetral light switch, not really part of the charging system. The yellow is not used. i am trying to find out why but it is always left disconnected.

[ganggreen]

cool

[electricchurch666]

Thanks -

[yep5510]

thanks brotha the video is cool.. but ihave a question. on my 1980 xs650 special i have additional wires on top of my strator housing. The wire colors are orange, black and grey. I really dont know how to wire these up also from the battery how do you run the wires to you spark plug coil to your ignition? Thanks again

[Smurph12586]

video will be very helpful. my question is if i have a 1978 xs650 (pre TCI) and have a PAMCO IGNITION do i need to unground the stator assembly with the nylon screws?

[thunzie]

Presumably, Yes. If you don't you'll blow your fuse right away because when you turn on your key-switch you'll connect the battery direct to ground. But if you're not sure just make sure you have a fuse in-line with the pos and if it pops as soon as you turn the key, you need nylon screws. Thats how I figured it out anyway :)

[drpeppero3]

i want to run my bike without the starter motor, my xs650 is completely stripped down,  so my question is, what do i save on the wiring harness when i buy a new one and what do i get rid of?

[electricchurch666]

you wont have to do anything to the new wiring harness other than cap off the wires that would connect to your starter relay.

[brooksidemech]

Great vid

[earlyshovelhead1969]

good vid dude.

'hanx!

[keythe856]

Great Vid. I just got done wiring my bike last week, then I found this . Fuck.

[electricchurch666]

no worries - you can always refer to the vid on the next project. 1 xs is never enough.

[raddonkey]

Thanks for this...

[PHUCNORRIS]

how come the stock ring terminal is still on the top left screw @ brushes? doesnt that ground that brush and defeat the nylon screw purpose?

[electricchurch666]

if you have tci, follow directions as recommended. If you have points, still follow directions as recommended. If it doesn't work, then refer to this video to potentially get you out of a jam).

Un-grounding the brushes is not always necessary in every wiring scenario. The ungrounded brush assembly is specific to wiring a stock tci reg/rec to a points motor.

If you don't unground the brush, you won't pull a charge (generally you aren't likely to damage anything if that is your concern)

[1roamin]

Thanks, I appreciate the help.

[1roamin]

Is it absolutely necessary to "unground" the brush assembly? What happens if I don't? I got a regulator/ rectifier unit from Mike's XS and I'm wondering what i should do as the instructions that came with the unit don't mention this step.