Go Back   Horizons Unlimited - The HUBB > Technical, Bike forums > Yamaha Tech

Yamaha Tech Originally the Yamaha XT600 Tech Forum, due to demand it now includes all Yamaha's technical / mechanical / repair / preparation questions.
Contact Overland Solutions for all your custom modifications and setup for overland travel.

Reply
 
LinkBack Thread Tools Display Modes
  #1  
Old 12 Nov 2009
Registered Users
HUBB regular
 
Join Date: Dec 2008
Location: Fife ,Scotland
Posts: 76
Can anyone tell me what this wire is??

As per the title im currently trying to rewire a 1996 xt600e that was previously stolen recovered and had no wiring loom when i bought it and have managed to make up one good loom from 2 old looms i sourced on ebay and now have pretty much everything connected up (I think!) except one wire! Its a black wire with a male bullet connector that runs from the loom along side the connector that goes to the starter relay and it seems to have nowhere to connect to??.

I have attached a pic with the wire circled in red.

Any help with this would be grately appreciated as ive spent the best part of a week trying to sort this out and am now stuck!!

Reply With Quote
  #2  
Old 12 Nov 2009
*Touring Ted*'s Avatar
Contributing Member
Veteran HUBBer
 
Join Date: Jul 2005
Location: Wirral, England.
Posts: 4,489
PM me your Email address and ill email you PDFs of the microfiches and the manuals.

I cant really see much from your photo. Its small and low res.
__________________
www.TouringTed.com
1994 XR650L
2001 NX650 Dominator.

BMW Dealer Technician
Welder/Fabricator

Ushuaia - Colombia 2007/8
UK- South Africa 2010/11
India 2012
Yukon 2012
S.E Asia 2014
U.K - Magadan 2015
Reply With Quote
  #3  
Old 12 Nov 2009
Registered Users
HUBB regular
 
Join Date: Dec 2008
Location: Fife ,Scotland
Posts: 76
yeah sorry about the photo, it was taken on my phone as my wife had the camera in the car!

Ive sent you a PM with my email address. The loom im using is from a 2000 4PT model, (the bike is a '96 4PT which still used the 3TB engine) I have electrical diagrams for a 1995 3TB and i think the only difference between the two is the starter relay? but they dont appear to show a lone black wire (its actually black with silver 'flashes' on it?) anywhere??

Ive managed to open up the other old loom I was canibalising and found out that the wire is actually the earth wire that connects to the rear of the frame with a ring connector just next to the regulator/rectifier although I still have no idea where the end with the bullet connector is supposed to connect to?
Reply With Quote
  #4  
Old 12 Nov 2009
BlackDogZulu's Avatar
Registered Users
Veteran HUBBer
 
Join Date: Oct 2008
Location: West Wales, UK
Posts: 759
On the 1994 600 there is a black wire where you say, and it goes to the sidestand switch. Just a thought.
__________________
2006 XT660R daily ride, 1994 XT600E about to be reborn, Blog: http://goingfastgettingnowhere.blogspot.com/
Reply With Quote
  #5  
Old 12 Nov 2009
Registered Users
HUBB regular
 
Join Date: Dec 2008
Location: Fife ,Scotland
Posts: 76
sidestand switch was my first thought but that is already connected so not that?! with it being connected to the frame at the other end it must be an eart for something but cant see what, will try to take a better picture in the morning and post it up to see if anyone recognises it
Reply With Quote
  #6  
Old 13 Nov 2009
Registered Users
HUBB regular
 
Join Date: Dec 2008
Location: Fife ,Scotland
Posts: 76
Thanks for the suggestions and help guys but ive now found out what the wire is!
After looking over the circuit diagrams again last night I noticed the solitary black wire that I must have missed when checking the diagram earlier (amazing what a couple of glasseds of wine can do!)

It appears that the wire is a secondary earth that goes directly to the battery and also has the front indicator earths spliced into it about halfway along the loom so just need to make up a connection to the battery and fix the snapped wire from the neutral switch that I also found last night and hopefully the XT thats been sitting in bits in my garage for almost a year might actually be running this weekend
Reply With Quote
  #7  
Old 13 Nov 2009
*Touring Ted*'s Avatar
Contributing Member
Veteran HUBBer
 
Join Date: Jul 2005
Location: Wirral, England.
Posts: 4,489
Quote:
Originally Posted by elv73 View Post
hopefully the XT thats been sitting in bits in my garage for almost a year might actually be running this weekend
Gotta love that optimism
__________________
www.TouringTed.com
1994 XR650L
2001 NX650 Dominator.

BMW Dealer Technician
Welder/Fabricator

Ushuaia - Colombia 2007/8
UK- South Africa 2010/11
India 2012
Yukon 2012
S.E Asia 2014
U.K - Magadan 2015
Reply With Quote
  #8  
Old 13 Nov 2009
Registered Users
HUBB regular
 
Join Date: Dec 2008
Location: Fife ,Scotland
Posts: 76
Ha ha, yeah ever the optomist!!

Wiring now all finished but the battery wont hold a charge so although it will turn over once or twice the battery then just dies, not really surprising though as the battery has been sat without a charge in a cold garage for the past year! Will order a new battery tonight

One thing i did notice is that I have no neutral light does anyone know if this would be a faulty neutral switch (checked the bulb its ok) before i order one tonight or could there be any other reason reason?
Reply With Quote
  #9  
Old 13 Nov 2009
*Touring Ted*'s Avatar
Contributing Member
Veteran HUBBer
 
Join Date: Jul 2005
Location: Wirral, England.
Posts: 4,489
Check the nuetral light sender is connected. A little nipple connector by the gear changer shaft.
__________________
www.TouringTed.com
1994 XR650L
2001 NX650 Dominator.

BMW Dealer Technician
Welder/Fabricator

Ushuaia - Colombia 2007/8
UK- South Africa 2010/11
India 2012
Yukon 2012
S.E Asia 2014
U.K - Magadan 2015
Reply With Quote
  #10  
Old 13 Nov 2009
Registered Users
HUBB regular
 
Join Date: Dec 2008
Location: Fife ,Scotland
Posts: 76
yep checked that as the blue neutral wire was snapped so have soldered in a new wire and all connections seem to be ok.

I have bypassed the clutch and sidestand switches so as a check i desoldered the wires for the clutch switch and the bike then wouldnt turn over which tells me that the bike thinks its in gear even when its not so wont start with the clutch 'out'.

Reading through some old posts it seems that this would indicate a faulty neutral switch so going to order one tonight and replace it, at least if that doesnt solve (really hope it does!)it its another possible cause eliminated.
Reply With Quote
  #11  
Old 13 Nov 2009
wolfzero's Avatar
Registered Users
Veteran HUBBer
 
Join Date: May 2009
Location: uk
Posts: 433
Quote:
Originally Posted by elv73 View Post
One thing i did notice is that I have no neutral light does anyone know if this would be a faulty neutral switch (checked the bulb its ok) before i order one tonight or could there be any other reason reason?
remember the neutral light is negative switched so check the bulb has an ignition switched positive on one side then eliminate the neutral switch wiring by puting a good negative to the termination on the switch itself if it lights ok then its new switch time if not its continuity checking time on the wiring loom
__________________
XT 630 SUPERMOTO

GSXR750L KMX200

RF900 & GSX400X Impulse Projects
3.9 V8 Rangerover
Reply With Quote
  #12  
Old 14 Nov 2009
Registered Users
HUBB regular
 
Join Date: Dec 2008
Location: Fife ,Scotland
Posts: 76
Quote:
Originally Posted by wolfzero View Post
remember the neutral light is negative switched so check the bulb has an ignition switched positive on one side then eliminate the neutral switch wiring by puting a good negative to the termination on the switch itself if it lights ok then its new switch time if not its continuity checking time on the wiring loom
Thanks for that, didnt think about it being negative switched, will go and check that this morning. Fingers crossed that its just the switch!
Reply With Quote
  #13  
Old 14 Nov 2009
Registered Users
HUBB regular
 
Join Date: Dec 2008
Location: Fife ,Scotland
Posts: 76
Checked the switch as advised and thankfully looks like its definatly a knackered switch , switched live to the bulb is fine and once the switch was earthed the neutral light lit up on the dash so looks like a cheap fix and just need a new switch.

Also glad to say that i managed to get a fresh battery on this morning and with fingers crossed pulled out the choke and prodded the starter button and guess what...........it fired up first time!!

To say im chuffed would be a massive understatement. A couple of weeks ago I was going to sell the bike as a non runner as I thought it would be too much of job to sort out the wiring get it going again.

I bought the bike for the paltry sum £250 as a non runner last year (due to the fact that it had no wiring loom) as a project for the time my ZX7R was off the road over winter without really giving much thought to the amount of work required and although ive bought various bits for it in that time ive only just got round to really working on it in the last couple of weeks.

Its tatty cosmetically, the silencer has no baffles and I still need to source a replacement frame as the existing one has had the numbers removed by the insurance company as it was a stolen recovered and was damaged in the process so cant be put back on the road (been looking on ebay for the past year but still havent managed to find one!) but really happy now that I know it runs ok so will strip it all down now and clean and refurb everything and hopefully will be able to source a frame and get it registered to go back on the road again. Actually now thinking of making it a supermoto but no idea what wheels / forks etc I would need or how hard it is to do the conversion so off to trawl the forum for information!!

Thanks again for the help guys and thanks very much for the manuals Ed

Cheers
Lee
Reply With Quote
  #14  
Old 14 Nov 2009
*Touring Ted*'s Avatar
Contributing Member
Veteran HUBBer
 
Join Date: Jul 2005
Location: Wirral, England.
Posts: 4,489
So whats it cost you in total to get it running ???

What more to get it through at MOT ?

Or shouldnt I ask !!!!!!!!!!
__________________
www.TouringTed.com
1994 XR650L
2001 NX650 Dominator.

BMW Dealer Technician
Welder/Fabricator

Ushuaia - Colombia 2007/8
UK- South Africa 2010/11
India 2012
Yukon 2012
S.E Asia 2014
U.K - Magadan 2015
Reply With Quote
  #15  
Old 14 Nov 2009
Registered Users
HUBB regular
 
Join Date: Dec 2008
Location: Fife ,Scotland
Posts: 76
So far to get it running has cost as follows (pretty much everything sourced from ebay):

Replacement air box and air filter as old one was damaged - £30

Wiring loom x2, both were bought with a degree of damage such as connectors missing / corroded wires etc so had to strip them both back and make one good loom from the pair - £60 total for both looms plus approx an extra £10 for heatshrink/solder/tape etc

Carb inlet rubbers £20

handle bar controls (kill switch, indicators, lights etc) - £25

Starter relay - £27

Oil, filter & spark plug - £33


In the end i managed to charge the battery ok. Charged it overnight in the house instead of the cold garage and it seems to be holding a charge ok so didnt need a new battery.

So, in total to get the bike to a stage where it now runs has cost a total of £205, plus the £250 purchase price brings it to a total of £455 so far.

However...its still a long way off being ready for an MOT yet, not least of all as it needs a new frame and I havent been able to source a frame with a V5 yet.

It also needs lights,(going to go for aftermarket parts rather than original Yam bits),indicators, new chain and sprockets, a silencer and the brake calipers completely overhauled so still a fair bit of work (and money!) to go yet but as i took a gamble in buying a non runner im really pleased now that ive at least got it to a stage where it runs so i know that the mechanicals are all fine and ive got the rest of the winter to hopefully source a frame and get the rest of the bits i need to get it roadworthy for sometime in the new year.

When I first bought the bike I had a budget in mind of £800 inc purchase price to get the bike roadworthy. Im not overly bothered about the cosmetics and am just going to paint the tank and plastics myself (satin black) so hopefully if I can eventually source a frame for a decent price then i should be able to come in somewhere around that mark. For the exhaust i'm considering just buying a cheap silencer from another bike and some flexi pipe and making up some brackets to make it fit (saw it done on another thread on here).

Im not after a show winning bike (although i do want it to look half decent), just a fun hack that i can sometimes do a bit of trail riding on as well as use during the winter while my ZX7R is tucked up in the garage and that if it gets dropped,scratched or dinged im not going to be too bothered about.

I know I could have probably bought a road worthy bike that didnt need much work for not much more than the finished cost of this one (or could I?) but I work offshore and do 4 weeks on and 4 weeks off and wanted a project that would give me something to do during the winter months when im not away at work and as the wife has a horse I have plenty of time to myself to tinker about with the bike during the day whilst she is at the stables.

So far ive really enjoyed getting stuck in and actually getting the bike to this stage so just have to hope that I can manage to source a frame now!!
Reply With Quote
Reply


Currently Active Users Viewing This Thread: 1 (0 Registered Users and/or Members and 1 guests)
 
Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On


Similar Threads
Thread Thread Starter Forum Replies Last Post
Wire Wheel Dingo Australia / New Zealand 7 14 Jun 2008 08:24
Wire Wheels Dingo BMW Tech 1 10 Jun 2008 12:00
steel wire cargo net ? mr moto Camping Equipment and all Clothing 11 6 Oct 2007 16:30
Wire harness Steiden Yamaha Tech 3 15 Sep 2007 13:20
XR400, whats this wire for?? colsan1 Honda Tech 5 17 Mar 2007 11:03

 
 
 

NEW! HU 2015 Motorcycle Adventure Travel Calendar is now available! Get your copy now for some terrific travel inspiration!

HUGE, 11.5 x 16.5 inches, beautifully printed in Germany on top quality stock! Photos are the winning images from over 600 entries in the 9th Annual HU Photo Contest!

Horizons Unlimited 2015 Motorcycle Adventure Travel Calendar.

"The calendar is magnificent!"

"I just wanted to say how much I'm loving the new, larger calendar!"

We share the profit with the winning photographers. YOU could be in the HU Calendar too - enter here!

Next HU Eventscalendar

See all events

 

HU DVD Autumn Special!

Take 40% off Road Heroes Part 1 until October 31 only!

Road Heroes features tales of adventure, joy and sheer terror by veteran travellers Peter and Kay Forwood (193 countries two-up on a Harley); Dr. Greg Frazier (5 times RTW); Tiffany Coates (RTW solo female); and Rene Cormier (University of Gravel Roads).

The first in an exciting new series, Road Heroes features tales of adventure, joy and sheer terror by veteran travellers."Inspiring and hilarious!"

"I loved watching this DVD!"

"Lots of amazing stories and even more amazing photographs, it's great fun and very inspirational."

"Wonderful entertainment!"

Check it out at the HU Store! Remember to use Coupon Code 'HEROES' on your order when you checkout.



Scottoiler automatic chain oilers. The most important accessory for your next motorcycle adventure!


Renedian Adventures


Renedian Adventures

What others say about HU...

"I just wanted to say thanks for doing this and sharing so much with the rest of us." Dave, USA

"Your website is a mecca of valuable information and the DVD series is informative, entertaining, and inspiring! The new look of the website is very impressive, updated and catchy. Thank you so very much!" Jennifer, Canada

"...Great site. Keep up the good work." Murray and Carmen, Australia

"We just finished a 7 month 22,000+ mile scouting trip from Alaska to the bottom of Chile and I can't tell you how many times we referred to your site for help. From how to adjust your valves, to where to stay in the back country of Peru. Horizons Unlimited was a key player in our success. Motorcycle enthusiasts from around the world are in debt to your services." Alaska Riders

contest pic

10th Annual HU Travellers Photo Contest is on now! This is an opportunity for YOU to show us your best photos and win prizes!

NEW! HU 2014 Adventure Travel T-shirts! are now available in several colors! Be the first kid on your block to have them! New lower prices on synths!

HU 2014 T-shirts now in!

Check out the new Gildan Performance cotton-feel t-shirt - 100% poly, feels like soft cotton!


What turns you on to motorcycle travel?


Global Rescue, WORLDwide evacuation services for EVERYONE

Global Rescue is the premier provider of medical, security and evacuation services worldwide and is the only company that will come to you, wherever you are, and evacuate you to your home hospital of choice. Additionally, Global Rescue places no restrictions on country of citizenship - all nationalities are eligible to sign-up!


New to Horizons Unlimited?

New to motorcycle travelling? New to the HU site? Confused? Too many options? It's really very simple - just 4 easy steps!

Horizons Unlimited was founded in 1997 by Grant and Susan Johnson following their journey around the world on a BMW R80 G/S motorcycle.

Susan and Grant Johnson Read more about Grant & Susan's story

Membership - help keep us going!

Horizons Unlimited is not a big multi-national company, just two people who love motorcycle travel and have grown what started as a hobby in 1997 into a full time job (usually 8-10 hours per day and 7 days a week) and a labour of love. To keep it going and a roof over our heads, we run events (22 this year!); we sell inspirational and informative DVDs; we have a few selected advertisers; and we make a small amount from memberships.

You don't have to be a Member to come to an HU meeting, access the website, the HUBB or to receive the e-zine. What you get for your membership contribution is our sincere gratitude, good karma and knowing that you're helping to keep the motorcycle travel dream alive. Contributing Members and Gold Members do get additional features on the HUBB. Here's a list of all the Member benefits on the HUBB.


Books & DVDs

amazon

All the best travel books and videos listed and often reviewed on HU's famous Books page. Check it out and get great travel books from all over the world.


Motorcycle Express for shipping and insurance!

Motorcycle Express

MC Air Shipping, (uncrated) USA / Canada / Europe and other areas. Be sure to say "Horizons Unlimited" to get your $25 discount on Shipping!
Insurance - see: For foreigners traveling in US and Canada and for Americans and Canadians traveling in other countries, then mail it to MC Express and get your HU $15 discount!




All times are GMT +1. The time now is 13:50.