Monday, 27 February 2017

XT500 rewiring or why there's no part 2 of the earles fork story today

If you ask people about me, they will most likely tell you that I am a mighty friendly guy, who, if asked politely, will most certainly "have a look at it", which more often than not, leads to fixing stuff. And that's just what happened. My mate Philipp called me and asked me (tongue in cheek), whether I knew a thing or two about rewiring XT 500s as his had literally the worst wiring loom installed I have ever seen.

As he bought everything new, it was a pretty simple and straightforward process to be honest and the pictures will only show you a few spots where you have to have a second look at things.

Space in the headlight shell comes at a premium, so make sure you route everything as snug as possible.

There's two single yellow and green cables, those are high- and low-beam no matter what colour they are on the aftermarket reflector.

Same goes for ground (black on the loom) and blue-red for the pilot light and green is ground for the main bulb. 

Rear is straight forward, green is the left indicator charcoal is the right indicator. 

As we did a 12V-conversion with a Roebi-Regler (google it, this thing's the dog's danglies for XTs and other 6V Yamahas), things came out a bit brighter than stock...

Oh and, no it's very unlikely there'll be much of an update on the earles forks tomorrow either, because my car (trusty old Volvo V70 station wagon) killed on of its driveshaft bearings and I have to do that next...


  1. There's no such thing as a 5 minute job!

    1. But credit where credit's due... that loom was pretty close. Roughly 3 1/2 hours from start to finish and we literally wired EVERYTHING up. (And most amazingly it worked immediately!)

  2. There's no such thing as a 5 minute job!