harness hopes

[Bob]

Hi All
Hoping for some wisdom

I am in Australia my XS is a 1980special model. The differences from the US models that I am aware of is that my bike comes with points ignitions (now changed to Boyer Bransden Electronic Ignition ) and a number of carb, clutch / brake differences that at this point do not mater.


I am having a number of electrical issues including unexplained failures to start, backfiring, and general loss of adequate spark. The boyer has been operating great guns for past 2 years and at same time i got VM34 Round slide carbs from 650 central


Based on the number of apparent electrical issues I am having I have decided on going with a new wiring harness from mikes xs however due to the differences in Australian/ UK Canadian and US models within the ”specials modals ” I do not know which one of mikes main wiring harnesses to order. As the fuse panel of my bike is also now damaged and it is a points model not TCI ignition am I correct in ordering mikes

Main Wiring Harness - Fits: XS650 2F/SF 1979.
OEM Ref.# 2MO-82590-51-00

Wire harness includes built in stock type fuse panel assembly.


And then expect some messing around with rear lights etc... I was hoping most switch gear etc would all be compatible and not too much of a hassle to rewire (after owning this bike for 10 years i should realise I live in a dream world )


Any information any one can give regarding the best harness for me to buy would be greatly appreciated


Cheers

Bob

[madmax]

Hi Bob

Might be worth contacting this guy here in the UK www.rexs-speedshop.com/?section=11311 , Marcus the owner is a well respected member of the SR500 forum and if I'm not mistaken runs (or has run) XS650's as well, he might be able to help.

Max

[Bob]

thanks max
appreciate you help mate,
I have sent off an email to Marcus however with the money exchange and ease of ordering i am keen on finding the right one from mikes xs if possible..... what happens and what is possible of course can be quite different.....

thanks

[ShakerNorm]

I have a 79, and recently replaced my wiring harness with one from Mike's. It is set up for points, but it's also set up for the old style mechanical voltage regulator and rectifier setup. With the 80 and up (at least in North America) those bikes had the electronic VR and rectifier setup.

With your Boyer box, modifying either the '79 or '80 wiring harness would be quite easy, but if you have the later alternator and electronic VR, the wiring is different between the two, and that may cause a problem when you go to swap it in.

The loss of spark may actually be your ignition - my Boyer had a Gill coil - and it fried out on me. Apparently, they aren't too reliable, so it might be worth checking the coil. When I checked the secondary side of mine, I got different resistance when I measured one way than I did when I reversed the leads. The should both read the same.

MrRiggs has a thread about swapping in a coil from a late-model GM FWD car that cured my problems. I expect that you could probably find a coil setup that is similar. There are also replacement coils for sale online or on eBay.

The main thing is to get a coil that is proper for your Boyer. The Micro Digital system will use 2 high resistance coils (about 3-5 ohms) and will always come in a RED box. The later Micro Power system uses a low resistance dual tower coil of about 0.6 ohms, and may come in either a red or blue box. It's easiest just to check the label....

[Bob]

oh god i hate when i have to ask dumb questions!!!!

thanks for the above info mate, but... how do i figure out if i have the old style mechanical voltage regulator and rectifier setup. With the 80 and up (at least in North America) those bikes had the electronic VR and rectifier setup. I'm looking for a link to a pic of a part so i can see what I'm looking for

I have the blue box boyer I got from 650 central so assume it is the right coils for the system... will go out and check them when i can.

the rest of the wiring would still benefit from replacement so i still seek a new harness

[ShakerNorm]

The mechanical VR will have a stamped steel cover (anodozed gold, probably) under the left side cover. The electronic version is a cast ribbed aluminum piece, but I'm not sure where it should be.

[xsleo]

The later combo reg/rec is mounted to the frame behind the rear engine mount.
Leo

[ShakerNorm]

Here's what it will look like.... cgi.ebay.com/ebaymotors/79-YAMAHA-XS650-XS-650-VOLTAGE-REGULATOR-/400201706480?pt=Motorcycles_Parts_Accessories&hash=item5d2de16bf0

They are adjustable - but it's a MAJOR Pain in the a** to do. - pry off the cover, start the bike, check voltage, adjust the VR, then as soon as you put the cover back on - it changes how the VR seems to work, so you have to remove the cover and start again..... it becomes a "repeat as necessary"..... which is usually 10 or 15 times.....

It was easier to do PamcoPete's mod and have the electronic one.... No more worries!

[Bob]

thanks guy looks like i have the older regulator as in the pic on ebay ... will have to find Australian equivalents for Pamcos replacement can some wise sole tell me how to test my coils and/or control box of my boyer B to see if that is my problem...cheers Bob

[ShakerNorm]

so the harness should fit to your VR and rectifiers without any problem, anyway. It might be worth looking into PamcoPete's mod to put an old style Chrysler VR onto your ride, though - it's pretty easy (if you can still get them down under) and pretty cheap too.

The coil I used was from a Chevy Corsica, so there should be some equivalent from GM there too. There were a lot of GM cars that used exactly the same coil pack setup.

Not much to testing the coil - check the resistance of the primary windings - they should be about 0.6 ohms. Not sure what the resistance on the Secondary is supposed to be.....

Here's Boyer's own troubleshooting page - www.boyerbransden.com/faultfinding.html. Not really much you can check, but that will explain it all.

Good luck

[pamcopete]

bob,

If you can't find an equivalent regulator in Australia, PM me your address and I'll send you one for cost plus shipping.

[Bob]

mate you rock...will see how i get on....cheers