Topic: Wiring in new controls

[mrbreeze]

Anyone up for a game of the proverbial "dog chasing his tail"? I just got the chrome handle bar controls from Mikes' XS (Yamaha 650) to put on my new euro bars and thought they would be pretty much cut & dried to install.WRONG!!!!....the switches are all the same and in the same location but I'll tell you.....I've been chasing wiring diagrams....both Honda and Yamaha and will tell you.....this is a big cluster F#@K as far as comparing to each other and to make it worse.....there are some major conflicts on both Honda & Yamaha diagrams. As someone here posted...don't even try to use a Clymers ....whoever put that together had his head way deep in his ass!!!! Conflicting colors,had the start button switch labeled as the horn etc. Then to really make it fun,Yamaha decided to muck everything up with all kinds of goofy safety swithes and such back in the later 70's. I figured on the wires changing colors but not all the BS light reserve unit,turn cancelling,etc. If anyone wants to compare notes as I dig a bit deeper, I'm more than game cause I will make this thing work. At this time,I don't have a decent Yamaha diagram on one page (been looking at several on the internet....scrolling up & down,left to right......major pain!!) also,I don't have my originals taken apart yet. I'm trying to do it all in my head and put it on paper so when I go to hook it all up,it should be straight forward.
Jonesy has a good write up in the FAQ's that helped alot so I may be referring to that as I go along. If any one has a decent Yamaha diagram,I'd love to see it....Thanks.

[crazypj]

Lots of fun isn't it
I'm doing the same thing on a 78 XS 650 (points model) with a 79 harness,(TCI), Suzuki /Yamaha instruments and some 'special' lights.
There are lots of different things going on
You can disconnect most of the safety relays, the reserve lighting device (under seat next to battery) needs the blue/black to blue /yellow bridged then lights work normally. I'm going to gut the stuff I don need.
PJ

[mrbreeze]

Yeah pj...I read somewhere on the Yami site about putting those two wires together. On the controls...isn't it one wire off of each control hooked together to by-pass the lighting reserve unit? I for one don't need that in my set-up. I will have a bunch more questions before I get this right but in the meantime...where is a decent wiring diagram that you can see all on one page without having to go buy a Yamaha book that might be as shady as a clymers is to a Honda?

[KB02]

I did the same with my bike, only I bought straight after market controls. It was nice that the back of the package had a wiring diagram for the control unit. I HAD NO wiring diagram for my bike.   

My advise - open up both the controls and draw your own diagram. That way you'll know what goes to what and where (Assuming that the stock control wire's colors will correspond the bike's wiring harness). That might give you a little bit of a heads up when it's time to splice and dice.

[mrbreeze]

I haven't opened up the switches yet to see what wire goes to what button or switch but I don't think that would help much anyway. The Yamis had some wierd things going on but I'm sure it will all turn out OK as I start putting it together. I will do a mock up wiring first with no power and chase through with an ohmeter to see if every wire does what it is supposed to do.

[chung]

A multi meter and a pen/paper should sort the new switchs, If you already understand the Honda then it shouldn't be" toooo" bad. I know little of the Yammi wiring to help, sorry there. But the Honda is fairly easy to get a grip on although the starter interlock can be confusing at first.

I'm thinking the blinkers would be the biggest pain, the self canceling relay on one of mine was over $80. Needless to say, it got changed to a $5 model

Good Luck Bro.

[mrbreeze]

Thanks Chung. Yeah, by looking at the Yami diagram, I would say the blinkers will be the hardest. I see the wires that go out to the signals but the inputs are a bit confusing. I have looked at various diagrams on the internet but have yet to find one all on one page and can't get my printer to break it down into sections. Its a pain trying to follow a line (wire) while scrolling left to right and up & down!! I read on the Yami site about jumpering the 2 wires that PJ mentioned which by-passes the reserve lighting unit(who the hell needs that anyway?) The cancelling unit is another part to be by-passed (my bad if I accidently leave my signal on). I already have the Honda end of it worked out. I'll get it one way or another. Talk to ya later.

[paxtonpony]

When I put 06 GSXR controls on my Honda I had to take apart the controls to see where the wires went.  I just used all bullet connectors and plug stuff in about 100 times till I got the results I wanted.  You can usualy elimintae stuff down to about 3 wires in any given group.  I had a really hard time because someone had rewired my bike and the colors were completely messed up.  Just be patient, you'll get it.

[mrbreeze]

Paxton.....I though of your post when I first went to do this. I remembered the pic. you showed with the wires all hanging down so I did a search and reread your post but realized you put late model controls on yours. I was hoping you did the same ones I did....76-78 Yami 650. Oh well....I'll get er!!! Like Chung said...Multimeter and pad & pen.

[paxtonpony]

Ya, I had some crazy grid sketched up on a sheet of paper to keep track of everything.  Wires numbered one way and electrical functions going the other way.  I had to use tape with numbers to keep all the wiring straight.  Being color blind and having faded wires doesn't make the task any easier (that's why I just numbered everything).  Good luck man!  It'll be worth it when you get done.  Everytime people ask about the bike I always point out the work I did wiring in the controls.  For some reason, I keep thinking someone (that doesn't own a CB) will be impressed.  Never happens.  Ah well, it's just one aspect of a bike I'm proud to ride every day.

[mrbreeze]

I'm also color blind.Thank god for multimeters!!!! There are actually only a couple of the colors I could get mixed up on though.

[chung]

The bity number tags are a MUSTHAVE, sorry I left that out. Any elect supply will have them. Way better than masking tape.

Power to the blinker should be easy enough? There may be two power supplies to that switch but one will be for the running lamps.

A little common sense can separate the two functions, even it they are working an 1156 bulb.

Another issue may be that the power is "blinked" before coming to the switch on the Honda and after the switch on the Yammer. Again, Sorry, I don't recall