Wiring Harness Repair

This is a must repair for all XN85's because of poor bike design. The problem is the floating suspension rubs the wiring harness causing shorts in the electrical system.

See how close the floating suspension is to the Y spilt in the harness? Second the metal protective plate tends to wear through after 20 years :)

Here is a better shot of where the protective plate wears.

As you can see my wiring harness had a cut at the green wire which caused my dash lights to go out as well as the running lights but not the head light. The white wire had a small nick as well.

I spliced the wire the cheap way with a wire connector.

Now here is the actual mod. You have to reroute your harness over the frame not under. You then have to ground the starter relay somewhere else as it used to ground to the metal protective plate over the wiring harness. I didn't cut this wire but instead wired it to the mounting bolt on the starter relay. I then used to tie's to secure it close to the frame.