Topic: 76k wiring conversion to accommodate 75k controls. Advice on options needed.

[Matty-Wan]

Hello all,

First, thank you taking the time to weigh in.  I have bought 75k repro hand controls to update my 76k.  As some of you experts may know, the headlight laws changed in between these years so the 76k hand controls have a somewhat different wiring schematic.  I am going to replace the wiring harness before I install the controls.  My question is this; Would I be better served to buy a 76k harness and modify the 75 hand control wiring OR buy a 75 wiring harness and modify that to work with my 76k bike?  Unfortunately this may require some more info since from what I have read there may be different wiring variations on the market depending what part of the year in 76 the bike hit the market.  Thanks for any insight and pro tips are always welcome!

best,
matt     

[BASKET_CASE]

What is the difference between hand controls?

It might help to show the wiring diagram of both the 75 and 76 version you have.

I combined the top and bottom of two different 550 housings  to create a unique control, but made my own harness. 

[Matty-Wan]

Well the most obvious differences are that for the 75k controls the connectors are all individual bullet while the 76k controls are mostly grouped together into plug-in connectors.  The biggest difference in function is the on/off for the head light is removed in 76.  After 75, CA declared all headlamps must run at all times for safety. This means the schematic is slightly different.  I am sure it is a fairly simple modification to make and one I planned on doing when I bought the wrong year parts until it occurred to me that modding the harness might be a better way to go. 

[BASKET_CASE]

The following sites should be able to address your rewiring needs as far as terminals or plug hosing is concerned

http://www.cycleterminal.com/index.html
http://www.vintageconnections.com/

Photos of your specific control and the wiring diagrams would be ideal to give any specific recommendation.