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Found 56 results

  1. 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
  2. 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!
  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'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!
  5. 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.
  6. 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 ?
  7. 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
  8. 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
  9. Hello guys I have a 2008 Honda xr650l I’m looking to install some led adventure lights on it my question is can anyone give me advice what the best place to wire into is? I was considering wiring into the blue and white ignition wire That is also the high low beam wire, it seems like a good candidate because when started switch is pushed it cuts power and also because i believe it will allow the lights to be on with both high and low beam. What are your guys thoughts can you confirm or deny any advice ?
  10. 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
  11. 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.
  12. 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!
  13. 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 $50 and it came with no wiring. I wanted to do custom anyways. I am converting to 12v with an antigravity 4cell 12v battery, 12v regulator, along with new oem style CDI, new coil, new pulse generator, ITS ALL NEW and fresh. I am not running any lights, all I need is to wire up the ignition and charging system, kickstart only. Problem is my new reg/rec has different colors than oem with no instructions, the coil I have has an extra wire compared to oem, I’m running a simple two wire on/off keyed ignition switch, subtle differences that leave me confused on where to go. Long story shortish, here is a list of what I have with color of each wire Any help you could give as to where to go with what is much appreciated, I know a few are probably obvious and simple but I’ll list them anyways for full coverage. Ignition switch (in-line fuse coming off of red wire, going straight to pos on batt) Black Red Reg/rec 2 yellow Red Black CDI Blk with female blade connector Two green Red/blk Blue/white Blk/white Pulse generator Blue Green Coil Blk/yellow Green Alternator Yellow/white Yellow Pink Red/black
  14. Just picked up a 2004 400 ex for 500$. 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?
  15. 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!
  16. 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
  17. 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.)**
  18. 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!
  19. 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.
  20. 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?
  21. 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.
  22. 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
  23. Guest

    2017 YAMAHA TR230 Headlight install

    Hi I have a 2017 ttr230 and I ordered a headlight and switch but I need a wire harness unless if anyone knows how to wire it a Different way. https://m.ebay.ca/itm/Universal-Dirt-Bike-Motorcycle-Vision-Headlight-Head-Light-Street-Fighter-Lamp-/332143818141?txnId=1501555486014 https://m.ebay.ca/itm/7-8-39-39-22mm-Motorcycle-Handlebar-Horn-Turn-Signals-High-Low-Beam-Headlight-Switch-/142470679622?txnId=1497984268004
  24. Just purchased a second hand Australian 1995 XR600R that was used for racing. Previous wiring harness was stripped back to bare essentials and I need to install indicators and controls. Previous owner now unresponsive. I pulled the stator to check it and it looks to be upgraded from stock, or rewound. Has mark ZC9 but can't find a reference to it online. Has three wires—two yellow, one black > white. Images attached for reference. I have a complete wiring harness of a standard Australian 1995 XR600R including CDI, regulator and rectifier, along with all controls, indicators, front and rear lights. But I've no idea which of the stator wires (2x yellow, 1x black>white) connects to what and if I need to purchase anything to make it all work. Any ideas what goes to where from the stator to the wiring harness? Thanks.
  25. So I got this crf50 and it does not have a killswitch and I got one coming in tomorrow. Could someone please help me /guide how to wire together i don't really know the exact wires to match up here are some pics!! And Thankyou
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