Comments on: xs650 charging system how-to

By: Cd

Cd — Wed, 22 Aug 2012 03:59:29 +0000

In reply to John Telvin. Did u ever get that 500 wired if so could u let me have the diagram

By: Scott

Scott — Wed, 25 Jan 2012 17:13:28 +0000

great video! i was wondering if anybody could help me figure out why i have power going to the rec/reg combo, but no power coming out???? charging issue? thanks

By: mookie

mookie — Thu, 17 Nov 2011 22:56:14 +0000

IF i understand this correctly then BOTH the brush wires from the stator are tied TOGETHER and switched.i’ve watched it a few times and that is what i get.
yes? no ? yall hope me!

By: Jeff

Jeff — Tue, 04 Oct 2011 21:44:51 +0000

I have a 79 650 special chopper but would like to wire the electric start back up. Was wondering if there is a simple wiring diagram I could get.

By: Dave @Chaparral Cycle

Dave @Chaparral Cycle — Fri, 19 Aug 2011 19:50:11 +0000

Great video. This should solve the problem with the ’72 custom we have in the shop. Where can we get the Rec/Reg? Tried one source & they are out. Thanks for you help.

By: Alan

Alan — Sat, 04 Jun 2011 07:27:49 +0000

Is there anyone that makes a wiring system that’s just a plug in and go? 81 xs650. Ignition, elec starter, front light, tail light and break light

By: sean from boston

sean from boston — Sat, 02 Apr 2011 13:48:10 +0000

wow great tech article

By: Rick

Rick — Sun, 27 Feb 2011 00:08:36 +0000

Found 4mm nylon screws at smallparts.com Comes in a pk of 100 for $9.

By: Rick Castor

Rick Castor — Thu, 24 Feb 2011 19:35:52 +0000

I am having trouble finding 4MM nylon screws, any suggestions where I can find them. Easiest wireing job I have ever seen. Thanks

By: Tim

Tim — Wed, 14 Apr 2010 23:28:14 +0000

Do I have to wire my ignition box back up?

By: Tim

Tim — Wed, 14 Apr 2010 23:27:06 +0000

im having the same problems mike. does anyone know if u have to unground the brushes on a 1982 with tci. Also I cant get spark back to my motor. does anyone know of a coil wiring diagram. I have a red green and black wire coming from my pickup. do i just hook those up to the coil? any help is greatly appreciated!

By: Mike

Mike — Sat, 03 Apr 2010 07:37:28 +0000

iI mean with having an eletronic ignition will i still have to unground brushes to pull a charge or no? Brian says its not always neccesary.

Thanx again

By: Mike

Mike — Sat, 03 Apr 2010 07:00:27 +0000

Thanx a bunch Ted. This info has been very helpfull. Do you happen to know what ungrounding the brushes actually does?

By: Ted

Ted — Fri, 02 Apr 2010 20:35:48 +0000

@ Mike Okay, “impression that there was something different goin on in the stator assembly on the 80s bikes than the 70s bikes.” You are correct. There are a number of differences in the xs between 79 and 80 forward. The 1982 YOU have does not have points, it has a electronic ignition box. This means that this particular wiring article will apply to you if you are re-wiring your bike. Click on the wiring diagram and then print it off and bring it with you to your shop. Then follow each wire like you were following a map with driving directions. Start with one component and work your way through.

“Also his video doesnt show the headlight or taillight wiring.” If there’s two wires coming out red and black. The red wire goes to your battery or to a switch than your battery. The black wire goes to ground. You should just go to the library and pick up a book on motorcycle electronics. Then, you’ll have a basic understanding and will be able to wire your bike and your buddies will call you for help.

It’s hard to give electronic help because there’s a chance that your wires are different colors than stock and they also have different wires for each year and I don’t have any of that memorized nor do I plan to. I hope that this helps a little.

By: Mike

Mike — Fri, 02 Apr 2010 17:58:09 +0000

Im sorry not factory electronics, I dont really know what im talking about. so please bear with me. I was just under the impression that there was something different goin on in the stator assembly on the 80s bikes than the 70s bikes. This is my first build and im totaly ready for wiring and im stuck. ive been trying to figure this out for two weeks now and just now seem to be on the right track. so do I need to unground the brushes on a 82 or no? whats the difference between the older motors and the newer ones? Does my bike have points in it? when i said factory electronics I just meant that the wires coming out of the motor have never been changed.

Thanxs Freedom

By: freedom

freedom — Fri, 02 Apr 2010 04:33:12 +0000

Mike getting frustrated doesn’t do anything. This wiring setup is for a custom bike not stock.

By: Mike

Mike — Fri, 02 Apr 2010 03:17:47 +0000

Do i have to replace stator screws with nylon ones on a 1982 xs 650 engine with factory electronics? stupid question but i have no idea what im doing. Also his video doesnt show the headlight or taillight wiring. Where do they hook up? ahhhhh! Can anyone help please?

By: John Telvin

John Telvin — Sun, 27 Dec 2009 01:36:15 +0000

Hi, nice video for the 650. easy to follow. my question, i have a 1977 xs 500 and wish to wire the same way. i believe the brush set-up is different. any help would be great. thanks, John —

By: W.Cooey

W.Cooey — Fri, 16 Oct 2009 18:51:13 +0000

SUPER Video! Simple, to the point, nuttin’ but the stuff! Was lookin’ for Triumph tech, but this’ll help on my next XS proj. If you do the Turn Sigs be sure to post!

By: stemsk8

stemsk8 — Fri, 10 Jul 2009 17:16:47 +0000

nice how to vid. where did you get your 4mm nylon screws? i’m going to give this a shot on my 77.

By: Hugh

Hugh — Fri, 10 Jul 2009 00:44:36 +0000

Beau…

If you want the simplest ignition system on the planet, check out Pamcopete’s stuff. 3 Wires, and you are up and running… I’m running his system on my re-phased engine, and I have no complaints, and even less wiring!!

By: beau

beau — Thu, 09 Jul 2009 23:18:10 +0000

hey man great video u really helped me a hole bunch i got an 81 xs 650 i,m building and i was wondering if any one knew if there was a video or would make a video BRIAN that shows how too wire up my points and coils to get fire back to this bike withh the less amont of wire.s … thats all this site really is to cool i will be posting pics of my project soon right know the frame is hanging from the roof of my buddys garage thanks again

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By: Todd Coen

Todd Coen — Tue, 07 Jul 2009 01:51:04 +0000

Will this same wiring set -up work with a boyer ignition on a 1977 stator? Would the nylon washer be needed? Also what gauge wire did you use?
Todd

By: rob

rob — Mon, 06 Jul 2009 14:39:34 +0000

Great video brother. I have a ’75 that is 98% complete. the only thing holding me back is the wiring. Completely frustrated and over my head. Your vid is super easy to follow but my rec/reg was removed and a Martek elec start was added before i bought the bike. How do i wire it up. HELP…

By: Jack RollinS

Jack RollinS — Tue, 30 Jun 2009 20:48:05 +0000

Hey Minnesota boys, any of you heading out to Sturgis this summer?
I also live in MN and would love to see some representing of the XS…

By: Brian

Brian — Tue, 30 Jun 2009 12:22:01 +0000

sweet tech video man, I am also in MN and currently in the process of building my bike, your video definetly helped. Thanks