Archive for the ‘Elec – Wiring’ Category

XS650: Ants’ PMA   Leave a comment

Sourced and installed the parts from an RD350LC PMA into my blue rat some years ago . Used. Old. And still good. Very happy with it.

A year or so ago I picked up a nice low mileage 77 D. Ridden a few miles every year. Complete paper record. Had some charging issues.

About this time Ants from the British XS650 forum began providing new PMA units for a good price. 200W. Complete with rec/reg, a rotor cone key that fit the original XS650 crankshaft and timing marks. (if trying the link dont be put off if you get a blank page – simply reset and it will appear – dont know why it does this but it happens to me all the time)

Ants’ PMA kit

Was pretty busy for a while and it sat. Eventually got a chance to blow the dust off and begin.

Checking that the stator screws were loctited in – Yes.

Sometimes this locating pin just wont come out. Easier to quickly modify the backing plate.

The pin sits at 6 o’clock so a simple line perpendicular to the horizontal gives the position.

Backing plate didn’t sit properly over the crankshaft seal boss so got busy with a file. Would have been quicker to head off to the workshop and chuck it in the lathe. Naya.

Took a little while.

Sits perfect now.

Cut-out and reshaping will be now be done during production.

Phase wires held in place with a clip. Used another on the plate screw to the right just to keep clear from the chain and secured cable with a frame tie just below the rear engine mount.

Also removed the blue neutral indicator wire from the old loom, resheathed it in 4mm isolating sheath and reconnected to the original position. (Plug connector upper left in next pic)

This is the original regulator. Remove it. The rectifier too. Sits under the battery box.

Remove the battery to release the rectifier.

Made a plate to mount the new 5 wire rec/reg in the original reg position so the fins didn’t block the airbox inlet. Would have welded tabs directly to the battery box but had run out of wire for the MIG. The 3 screws with nuts create an air space under the rec/reg for cooling and better air flow to the filter-box. Packed with rubber bushes they dont rub against the underside of the rec/reg.

Fits snug between the tool box and filter-box. Cables separated, resheathed and fitted with original connectors.

Release the original connector blocks by inserting a small flat bladed screwdriver into the recess beside the pins. Simply push out.

Make sure the tangs are reset before reusing.

All connected. Added a 20 Amp flat bladed fuse holder in the positive battery feed. Just for security. This wire is too long and will be reworked.

The rec/reg, when mounted on the plate, interferes with the sidecover. Modified an old sidecover. Rattlecan-blacked it and it’s mate. Be a shame to mess up a good set of covers

Just got to put some kms on her now to road test before installing a 750 kit that’s been sitting on the shelf for a couple of years.

Had some charging issues in the beginning. Went through and checked the new wiring. Not quite sure what was wrong but the issues disappeared.

More than happy with this.

Update … almost killed my second rear tyre now – no problems – running sweet


XS650: AMP Superseal   Leave a comment

After parking the sidecar in town the other day I came back to find the sidecar front blinker and riding lights both broken. Decided to replace all sidecar lights with LEDs.


yellow blinker … white riding light … 3 LEDs each … both for the front … 0.004A/0.5W … non-polarised (can be wired either way)


rear light … 5 LEDs each function … tail/brake/blinker/number plate … 1W


As the wiring is rather exposed I thought I would try the waterproof AMP Superseal connectors. These come as 1 to 6 pole. Didn’t come with montage instructions. I found these pretty fiddly to put together. So went looking for instructions. amp superseal 1 and amp superseal.

Made the job a lot easier. However for the cost and effort I am not sure whether I would do it again. Simply from an installation and cost perspective I am disappointed. Time will tell how effective they are. If I hadn’t already the proper crimping pliers I wouldn’t have bothered – they are absolutely necessary. I used 1×3 pole, 2x2pole and 2×4 pole connectors. Together they almost cost more than the lights.


AMP Superseal type A .. cable 0.5mm² .. OD 1.2-1.6mm


AMP Superseal type B … cable 0.75-1.5mm² … OD 1.7-2.4mm


AMP Superseal type C … cabel 0.75-1.5mm² … OD 2.5-3.3mm … these red plugs come also as blind plugs (no hole through the middle)


Posted January 21, 2013 by xscafe in Elec - Wiring

Tagged with , ,

XS650: Voltage Drop Troubleshooting Tips   Leave a comment

Was rooting around in some old technical stuff. Found this. Some basics tips for troubleshooting Voltage Drops. Mess around with XS650s for long and you will know all about these.

Voltage Drop Troubleshooting Tips


page 01


page 02



page 03


You will need at least one of these…


multimeter – volts ac/dc – ohms


Freaky shit? Need a tutorial? How to use a multimeter.

XS650: LED Blinkers   Leave a comment

Got given a set of LED Blinkers a while ago. They sat around a bit. The idea was to reduce the load on my mates standard wiring XS. The low draw meant the flasher relay wasn’t registering them. He wanted to insert inline resistors. Increases the line load.  Defeats the purpose of using LEDs.

Had a Kellermann load independent flasher unit sitting on the shelf. Worked fine. Can also get generic models. 3 pole or 2.

generic 2 pole load independent flasher unit


led control lights … blinker is left


Did have to sort another problem though. The control light. Also LED. System wouldn’t work until Left and Right were separated by diodes. 1N4001- 1N4007.

  • 1.0 Amp forward current Silicon S general purpose diode,
  • Low forward voltage drop (ca 0.7V).
  • High surge current capability rectifier.
  • The only difference is in the maximum repetitive reverse voltage …  1N4001 has a maximum repetitive reverse voltage of 50 V, 1N4007  has 1000V.
  • 1 stands for number of semiconductor junctions. N means it’s a semiconductor diode


how I wired them in … the diodes (1N4001/4002/…/4007) separate the signal to the control light – works for LED and non-LED circuits


Your electronics bloke should be able to help. The end with the stripe is the output side.

The self-cancelling function doesn’t work anymore. Disconnect the yellow/green wire.

Posted February 3, 2011 by xscafe in Elec - Lights, Elec - Wiring

Tagged with , , , , , ,

XS650: Simplified Electrics   Leave a comment

There are distinct advantages to doing this. Original looms had circuits, relays, safety devices, checkers and stuff that did their job back then.

Time, vibration, water, oxygen and irregular maintenance have all compounded producing electrical systems, already lacking good fusing, that will provide you with endless hours of frustration.

I rip them all out. Can’t be bothered with the drama. Make them new. Myself. With central blade fuse box. 1 for each circuit. I get a new system. Custom designed for whatever I need. Easily modified. New cables. New connections. Soldered. Crimped. Isolated. And I know what I have. Diagnosis become heaps easier.

First time you’ll freak. Second time you’ll wonder why.

Here is one of the best. An all rounder. If you can look at this and understand it you will know more about original electrical systems than most. It is elegant in its simplicity. Plug and play. Except for some peripherals it’s all there. Thanxs Jayel.

Jayel put this together, earns a beer from me…everything really except indicators…for original charging systems and ignition

Simple to adapt for pretty much anything.

doesn’t get much simpler than this…no battery, runs capacitor, permanent magnet alternator, twin coil, pamco, no real need for the key though-could put a second kill switch somewhere

The only thing simpler is total loss.

Good earth connections. Check your brushes. Maintain your battery. Fuses.

Note that if installing coated bars you may have problems starting. Check your kill switch earth connection. No earth. No go.