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Found 54 results

  1. So here is my conundrum - I have wired up my own harness for my enduro package as I did not like the Tusk version with lots of things I did not want or need. I've wired three different bikes and can read the wiring diagrams fine - even designed/built my own 12V harness with capacitor for my 1970 CT70. Back to the issue - everything works with the exception of my 12V aftermarket horn. I tagged off the blue wire for the headlight (headlight works fine) and sent it to the horn button and then to the horn and then grounded back to the wiring harness. When I press the horn button the light dims and the horn barely sounds - meeeep meeeep. I checked the voltage draw and its only like 1.7V to the horn. Just awful and wont pass DMV to get my street license plate. So I put on my thinking cap and drew on my experience with my CT70 (solid state with a capacitor instead of a battery) and I think the absence of a battery is likely the culprit on my XR400 as it typically evens out the voltage draw on the system (similar to the battery) to provide power to all components. So my question is what if I put a 0-25V 22,000uF capacitor (like I used on my CT70) on the White/Yellow wire coming out of the AC regulator that eventually ties into the BLUE wire that feeds the headlight, horn and rear running taillight? Would that provide the stabilization for the voltage draws when I use all of my accessories? Thanks for any help.
  2. I've run a 125cc Lifan engine on my pit bike for around a year now, and it has performed really well. I decided to wire some lights to the bike and I faced some problems. The engine came with all the electric components and wires required for ignition, and it also has a light coil in it from the factory so I thought wiring some lights should be easy. I made a very simple wiring for the headlight and the tail light (picture of the diagram attached) and I used a multimeter to check the connection between ground and the wire just after the regulator. Results were good, switch worked just as I thought. Then I installed the light system to the bikes wires. I read from somewhere that the red wire coming from regulator is a power wire (12V) and can be used for different components like lights. So I went on and connected the red wire from the regulator (which by the way had nothing else attached to it before) to the light system, powered the engine up and I got no light at all. I checked the voltage on the red wire while the bike was running, and it was around 6 volts. This surprised me as the regulator that came with the engine was supposed to be regulating the voltage to 12V. I have a couple questions: How many volts come directly from the yellow light coil wire? is the wiring on my light system wrong or is this all happening just because of the weird regulator? Many thanks!
  3. Hi all, some help is required. I have bought a Ktm exc200 which i am very happy with. Thr previous owner had removed most of the wiring needed for the lights and horn etc and i want to get it working again so i can get an MOT and green lane it. The instruments still work but it looks like the wire to the rear brake has been cut at the master cylendar. See the attached pic, can anyone tell me what the connectors are for?
  4. i have a 2002 drz400s with the stock tail light. the running light works but when i go to press the brakes the light doesnt get brighter. ive changed the bulb out and it is still the same. when i turn the parking light on the light does get brighter. ive tried jiggling around some wires but no luck. ive read some other threads saying it could be a switch but im not sure on how to check if the switch is bad. Thanks in advance
  5. Hi everyone and merry chrimbo to all. Ive pretty much finished my resto project and everything’s great apart from the dim lights. I bought the bike with the problem, and thought it would be an easy fix. Nothing seems to fix the fault. So far, I’ve replaced the whole wiring harness, the rear light and wires, brake light switch and wires, front light holder and wires, speedo cable and wires. All 6v bulbs and I even had the light coils checked and replaced. So everything has been done apart from the handlebar switchgear. I had the frame powdercoated, but sanded the main earth point for the harnsess, so it’s a good earth. Even, ground two points of the five engine mounting points away hoping that might help. All the electrics work like they should including the pass light, just dim lights. Has anyone had this problem? Does the engine need to be grounded at every point? I thought if the engine had one good ground that would be enough. Really at a loss with this, and if I can’t sort I have to admit defeat and had it over to an auto electrician ?
  6. Honda XR650L wiring diagram. Here in .jpg, but available as .pdf and also (via link below) in .odg drawing format with layers, editable in LibreOffice format which is a free open-source software suite. I made this because the only diagrams I could find were real low-res ones and I wanted to be able to edit the diagram to account for changes I've made myself to the wiring. https://drive.google.com/drive/folders/1fyhLKkqjSWUfDFpjXMVDqI5m1-FqfOYj?usp=sharing
  7. I need to replace the plug on the wiring harness that connects to the tank of a YZ450F. I've got the tools to crimp terminals, so installing a spare connector would be easy. However, I can't find it as a separate part, and don't want to buy an entire harness. Any suggestions for finding this part? KTM publishes a list of spare connectors for their bikes, but I could not find anything like this for the Yamaha. Thanks in advance!
  8. Hi everyone, First time poster long time listener. I picked up a 1977 xl100 project for my wife this week and my intention is to turn make it a strictly off road bike. No lights, kick only just the absolute minimum. The bike as it stands is "missing" its wiring harness as well as it's rec/reg, fuse box, battery tray and more. Assuming that the components I have work(coil, stator, contact breaker), I need to know: -will I need a battery -what other components would I need and or can I do away with. -is a custom wiring harness something a wiring NOOB could build -is there a custom wiring resource
  9. Hey guys, im in need of some wiring help, and understanding the diagram on my 07 TE450. I need to get the front and rear signal LED lights to work, but it looks like the PO removed the relays. I'm not really sure how to proceed, the wiring diagram shows different colors from what I'm seeing in my bike, for instance, I've got a yellow orange and three reds coming out of the starter relay. And I don't see that on the diagram. I've searched the forum but up to date info on this old bike is pretty scarce, lots dead links. Is there a way I can just test the wires with a multimeter and figure out what they are? What's the best way to do that. I'm totally new when it comes to wiring. I just unwrapped those bare wires from some seriously old and sticky electrical tape. Thanks!
  10. Hi I'm Shelby, and new to the mechanic world. I just shimmed my valves, cleaned the carb, and rebuilt my water pump. Started it up and it fired up first kick. Ran for ten minutes and died. Wouldn't start for about ten min. Once I let it sit, it started back up and ran fine. Then died when it got got again. I checked the stator and it reads 17 ohms. The other wire read 240 ohms. What else could it be? Could the stator still be shorting out when hot? thanks for the help in advance!
  11. Is where a way i can wire something up to put a lightbar on my 2004 crf450r without spending big bucks? Has anyone done it? How did it come out?
  12. Does anybody know of any wireless headlights that mount where your number plate goes where you don't have to wire anything? Kind of just like push a button and it turns on type of light thing? I would also need it to fit my 03 cr125. Thanks for looking!
  13. got tired of dealing with 4 lugs screwed to each terminal on battery. dual sport kit, cooling fan, battery tender + oem lugs. ordered fuse box kit from eastern beaver. http://easternbeaver.com/Main/Wiring_Kits/Fuseboxes/3_Circuit/3CS-Sealed/3cs-sealed.html
  14. I am converting my 2005 Honda crf250r dirt bike into a street legal supermoto but have run into a problem. I used the tusk lighting kit and upgraded stator to do the conversion. Everything is working on the bike, turn signals, computer, taillight, on/off switch, ect. except the headlight!! I simply cannot figure out how to wire it to the tusk harness. Since its a race bike, it didn't have an existing headlight. The headlight I bought is the Poliosport Halo. Included are the diagrams to the headlight and the handlebar switch. If someone could explain how to go about wiring the headlight I would really appreciate it.
  15. Hey guys, I really appreciate you taking the time to read this and possibly give me some help. I have a 1979 Honda XL185s that I have rebuilt and am to the point of wiring it up. I picked up the bike for $50 and it came with no wiring. I wanted to do custom anyways. I am converting to 12v with an antigravity 4cell 12v battery, 12v regulator, along with new oem style CDI, new coil, new pulse generator, ITS ALL NEW and fresh. I am not running any lights, all I need is to wire up the ignition and charging system, kickstart only. Problem is my new reg/rec has different colors than oem with no instructions, the coil I have has an extra wire compared to oem, I’m running a simple two wire on/off keyed ignition switch, subtle differences that leave me confused on where to go. Long story shortish, here is a list of what I have with color of each wire Any help you could give as to where to go with what is much appreciated, I know a few are probably obvious and simple but I’ll list them anyways for full coverage. Ignition switch (in-line fuse coming off of red wire, going straight to pos on batt) Black Red Reg/rec 2 yellow Red Black CDI Blk with female blade connector Two green Red/blk Blue/white Blk/white Pulse generator Blue Green Coil Blk/yellow Green Alternator Yellow/white Yellow Pink Red/black
  16. well hello all, seems like forever since I posted last. and it has been five years. wow! at least I never quit reading all the posts. as I fix OP's XR's (doing lots of wiring esp) I have noticed that almost all the bikes have an original Honda harness with the dual sport wiring laid over it. most dual sport kits supply new leads for the positive side of new lights etc but most often the add on stuff tags into the Honda GREEN ground wire. the Honda harness had little to control so there is one small (I am hard pressed to call it 18ga) GREEN ground wire running end to end in the harness with a branch off it to frame ground at the coil mount. darn near every harness I look at has a pretty sad looking "branch" wire. that is, the wire is all discolored and brittle from being overloaded. so my thought on this is to remember to inspect that wire when you find yourself having electrical issues... it may not be the cause of your problem but that's a perfect time to check it out and upgrade it. I cut the old wire out any time I remove a tank. feel free to get proactive. have a dandy! neil
  17. So as I'm adding more and more auxiliary accessories to my Wr450f, I'm running out of room on the battery terminals to connect things. I've seen some "power distribution blocks" but theyre all made for huge 0 gauge wire. Anybody have any ideas of what I could do? Or something like this, but for much smaller wire. Like 20 gauge.
  18. Just picked up a 2004 400 ex for 500$. As I got it home and was looking I found this random wire hanging down, (circled in red) it obviously doesn’t go there and was wondering what the heck it is? Also the spot circled in green there’s a little bit of exposed wire, is this a problem when washing? Is there anything I should know before washing the bike?
  19. I recently broke my kill switch on my Honda Crf50 Pitbike. A replacement is on it's way, and I'd rather fix it myself than pay $48.00 of labor... (rip off). Does anyone know how to properly connect the new kill switch? Is the connecting piece behind the front number plate, or do I have to take off the gas tank and seat to wire to the CDI? Thanks in advance. ------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------ **(I was going to upload some pictures so you know what I'm working with, but I can't seem to download the pictures. I'll upload them if I can figure it out.)**
  20. Hi, I’ve been trawling through various forums and Facebook trying to find out what my problem could be. I was hoping some previous threads were going to give me a solution, but no fix yet. Brothers bike won’t start. It will spark every 5-10 kicks. If I kick slowly right on the top of compression It does go. But when kicking repeatedly it doesn’t work. (With and without 12V external supply) We have a second bike at a neighbour which we tried components swapped over. All fine. Tried in the dealer power supply and LED FI and showed no faults - confirmed by trying off various sensors to force a fault. Loop tested each circuit at sensor. And then though wiring loom to ecu. Resistance and Continuity ok. Followed manual for min peak volts from ckp and rotation sense with a made up peak voltage sensor. Ok. Just. It’s charging 12v ok and capacitor ok. Confirmed in bike and bench tested charge and discharge time. Ecu swapped- no difference. TOS/Kill ok. Wiring loom removed and checked over line by line and continuity checked. Ill attach photos of inside of stator/rotor. I think that the CKP/Stator set up has something wrong with it. I think stator ok, but the rotation sense/CKP pick up not working. Im not sure what the start permissives would be on the bike, but I think I’ve covered them all. I’m not sure how the ECU works either....does it look for rotation to start fuel injection for example or does it look for rotation and CKP before ignition. I did notice some slight scoring on the inside of the casing. The stator went away for testing which goes against me think that it’s the CKP/Stator assembly. I thought perhaps rotor, but it’s a nice strong magnet. Hoping to swap stator and see how we get on. TIA for any thoughts on this.
  21. Hello all, I recently purchased this light and this wiring harness kit. I know the wiring harness wasn't the cheapest route to go, but I don't have a lot of electrical knowledge and I wanted to make sure I had everything correct. Could anyone please tell me where I'll be plugging that 12v relay into? That's the only connection that I can't figure out. Thanks for the help. https://www.amazon.com/gp/product/B071SKD7SY/ref=oh_aui_detailpage_o01_s00?ie=UTF8&psc=1 https://www.amazon.com/gp/product/B01B5UXWY4/ref=oh_aui_detailpage_o01_s00?ie=UTF8&psc=1
  22. Hi all, Will from Melbourne in AUS and I am pleased to finally join ThumperTalk. I'm 9 months into a custom build transplanting an '81 XR500R into a '81 CB250RS and I'd like some advice. I'll start with my question which is a fairly simple one, and then follow up with an answer to some anticipated questions which might help understand what my issue is and what may be causing it. MY QUESTION: Does the CDI box or CDI black box igniter (shindengan) from the CB250 run the XR500? or put in a different way, does the xr500 motor need its original cdi box (which is a round metal box) compared to the rectangular rubber one off the 250, in order to fire? Thanks in advance, Will -break- MY PROBLEM: I can't get the XR500 started, even though it has just had a full-rebuild inc. bore/piston/valves/hydroblast, spark, good fuel, carb-kit, and it was built using torque wrench and some precision around building it which is why I'm surprised it didn't fire straight away. ANSWERS to potential Questions are; 1) What has been blended together between the two bikes? 2) Why on earth am I building a cbxr500rs...? 3) More depth around the issue please? 1) What has been blended together between the two bikes? First off, I used the cb250 wiring loom because it was complete and ready to run the lights which the xr doesn't have. The cb250 & xr500 motors share side covers, and some other parts. Because I want a lighting system and given the XR doesn't have an alternator or wiring for a lighting system, I used the alternator from the 250 which bolted straight into the 500 replacing its original magneto. The Alternator from the 250 is also a bit lighter so it may improve performance. I used the side cover and wiring from the 250 on the same Alternator side for 2 reasons: i) because it was in better condition and, ii) had the wiring plug to go straight into the loom from the 250 as well. A perfect match so it seemed. On the right side, given I had just replaced the pulse-generator wire from the 250 before it died, which cost $100 bucks, and the side cover was once again in better condition (and matched the 500), I used 250 right side cover and its pulse generator on the xr500 which also means it can plug straight into the loom as the xr500 motor had no plug on the end which saved me mucking around. Motor/Running Gear: cb frame & front Yend, xr motor, xr carb, xr rear-wheel to retain ratios, 2 into 1 exhaust from the xr500 which has been custom modified to be 2 into 1 into 4 under the seat! (for looks mostly, although careful attention to pipe diameter taken to retain back pressure and exhaust velocity). The XR500 motor has a new 10.5:1 piston, stage 1 bore to 89.25mm, valve-grind/resit/lap and hydroblast, all new other parts plug/gaskets/oil/seals/carbkit etc etc, xr500 sprocket, weld another row of bars above the frame to accomodate the carb and seat, custom fab on frame/seat etc to accommodate. May make an airbox for it if I think its required. Wiring: cb250 Loom (xr had none), lights etc from the cb250, Regulator Rectifier from the 250 (of course because it is designed for the power of the alternator), but I used the Coil from the 500 motor which is smaller, as the bigger one from 250's was stuffed, Fuses from the 250. *However, I used the CDI box off the 250 (not the 500) because it could plug into the loom, and this is where my question lies? 2) Why on earth am I building a cbxr500rs...? Well, I'm sentimentally attached to the cb250 which I built as a learning project 5 years ago, and I read the xr500 motor fits in the frame and saw someone in the UK which transplanted it I was pretty intrigued. When the cb250 finally died it was a perfect opportunity to hunt for a donor bike and put the xr500 motor in, and also a perfect opportunity to do any modifications/upgrades and servicing to the cb bike which I had originally built on the cheap and now happy to sink money in it. 3) More depth around the firing issue please? It has spark, but won't fire and start even though it seems it really really wants to. Given a fair amount of precision went into building the motor I'm surprised it didn't fire in the first couple of kicks and I've since spent a bit of time trying to get it started to no effect. I'm tempted to check ignition timing using one of those lights, although the one I have is not designed for bikes but cars instead and is a pain the ass to get rigged up!
  23. Hi, I'm hoping someone can help? Have just put together a 1983 PE 175 and bike runs fine, lights are slow to come on and dim. Brake light blows when applied and horn pretty asthmatic too. If I disconnect one either light and the other goes nice bright. Other than I nailed it!! Have checked wiring against a diagram I found on the net and all the wires are where they should be. Checked the connectors on the light related wires and cleaned. Also ground the powder coating back on the earth point. Really haven't got a clue why it the way it is. Any help will be much appreciated, as I spend most nights doing the same thing over and over again which is a little underwhelming. Cheers waz
  24. Hi guys I have a bit of an issue that I am hoping you can help me (and more importantly, my 11 year old son) with. I can ride a dirt bike but am apparently useless when it comes to electronics! Here's the deal: My buddy gave me this Honda Z50R. He said it runs fine but needs a new air filter and some other minor parts. When we got it home, we realized that the engine is not the original - instead it's a bigger, Chinese make Lifan motor. Whoever installed it before did some makeshift wiring and this is my problem. My son may have disconnected a wire and there is no spark when trying to kick start it. We replace the spark plug, to no avail. One thing that is notable is that the kill switch is only connected through the black wire and the green wire was capped/tapped/disconnected. does this make sense? I also assume that the original had an ignition and possibly a headlight which may explain the yellow, white and/or light blue/red wires that are coming from the engine, disconnected. I know it is difficult to figure it out looking at two photos but if you have any idea please share it. Thanks a lot! Ogabott & Owen
  25. I have a 2006 Suzuki DRZ400s. I am having an issue with the tail running lights not working. The brake light does work with both the foot and hand brake. The running lights will come on when i turn the key past run to the park setting. It does have an aftermarket led tail light. Any insight would be appreciated
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