HOW-TO: R6 Controls added to FZR
Posted: Sat May 24, 2008 8:39 pm
So I have half if it done. I have the throttle side on and working. It was super easy to modify the R6 controls to accept the fzr throttle cables. Beyond that it was some simple wiring.
The R6 throttle cables are way to long for the fzr so the stock cable must be used. After getting the R6 controls off I had to drill out the left hole so that it was circular. Not sure what side drill bit I used but my fzr cable housing fits in there incredibly snug. No worries about it coming out. The stock fzr C shaped washer/clamp thing bolts right up to the R6 control to lock in that side of the throttle cable. The right hole needed to be tapped to accept the FZR return cable. I used an M8 tap and it screwed right in. That's it. R6 controls for a nicer look and updated internals.
On the throttle controls there was a goofy little pin on the inside that kept them from seating on the bars correctly. My guess is the R6 has a hole drilled in the handle to allow this pin to drop through and there will be no worrying about the controls moving. I just grabbed it with some pliers and yanked it out. It's just glued in. I'm working on the left side controls and will post when I have them working. The wiring is a lot different so we shall see if it works. I'm hoping.
Update!!!
I have the answers to the wiring issues on the controls. Now here are some things you need to know first -
1) The headlight is wired permanently on once you move the key to the on position. Hitting the start button will not cut off the headlight to make more power for the starter and coils. This is easily solved by upgrading the coils to the ford coil pack.
2) I'm not sure there is a two.
The right side is the easiest to wire so we'll start there. BTW, I'm thanking Naes right now cause he walked me through all this. Cut off the FZR plug from the controls, you'll be reusing it. Now cut off the plug from the R6 controls. Strip all the wires and get ready to solder them together. This is how it's going to connect. The FZR uses 2 red/white wires for the kill switch. They are designated below as to how you hook up the wires from the R6 to the FZR for those wires.
FZR Wire Color------------------- R6 Wire Color
Blue/Black to Red/Yellow
Blue/White ----------------------- Blue/White
Green/Yellow--------------------- Green/Yellow
Black------------------------------- Black
Brown------------------------------ Brown
Red/White------------------------- Red/Black (Connects to the corner red/white on the FZR plug)
Red/White------------------------- Red/White (Connects to the middle red/white on the FZR plug)
Left Side Controls
FZR Wire color----------------------- R6 wire color
Yellow/Red to Black----------------- Black/White
Blue/Black to Green----------------- Red/Yellow
Yellow--------------------------------- Yellow
Brown--------------------------------- Pink
Brown/White------------------------- Brown/White
Chocolate---------------------------- Chocolate
Dark Green--------------------------- Dark Green
(Sorry no picture for this side.)
That's everything. It took some trial and error but everything is sorted out with this setup. The low beam will stay on all the time. The hi-beam switch will add the hi-beam light and the low beam will stay on as well so for those of you running non stock headlights this may or may not be an issue. It will depend on the load being drawn if both lights are on. Anyhow, hope others go for this swap. It's kinda nice to have 13 year newer controls on my bike!
The R6 throttle cables are way to long for the fzr so the stock cable must be used. After getting the R6 controls off I had to drill out the left hole so that it was circular. Not sure what side drill bit I used but my fzr cable housing fits in there incredibly snug. No worries about it coming out. The stock fzr C shaped washer/clamp thing bolts right up to the R6 control to lock in that side of the throttle cable. The right hole needed to be tapped to accept the FZR return cable. I used an M8 tap and it screwed right in. That's it. R6 controls for a nicer look and updated internals.
On the throttle controls there was a goofy little pin on the inside that kept them from seating on the bars correctly. My guess is the R6 has a hole drilled in the handle to allow this pin to drop through and there will be no worrying about the controls moving. I just grabbed it with some pliers and yanked it out. It's just glued in. I'm working on the left side controls and will post when I have them working. The wiring is a lot different so we shall see if it works. I'm hoping.
Update!!!
I have the answers to the wiring issues on the controls. Now here are some things you need to know first -
1) The headlight is wired permanently on once you move the key to the on position. Hitting the start button will not cut off the headlight to make more power for the starter and coils. This is easily solved by upgrading the coils to the ford coil pack.
2) I'm not sure there is a two.
The right side is the easiest to wire so we'll start there. BTW, I'm thanking Naes right now cause he walked me through all this. Cut off the FZR plug from the controls, you'll be reusing it. Now cut off the plug from the R6 controls. Strip all the wires and get ready to solder them together. This is how it's going to connect. The FZR uses 2 red/white wires for the kill switch. They are designated below as to how you hook up the wires from the R6 to the FZR for those wires.
FZR Wire Color------------------- R6 Wire Color
Blue/Black to Red/Yellow
Blue/White ----------------------- Blue/White
Green/Yellow--------------------- Green/Yellow
Black------------------------------- Black
Brown------------------------------ Brown
Red/White------------------------- Red/Black (Connects to the corner red/white on the FZR plug)
Red/White------------------------- Red/White (Connects to the middle red/white on the FZR plug)
Left Side Controls
FZR Wire color----------------------- R6 wire color
Yellow/Red to Black----------------- Black/White
Blue/Black to Green----------------- Red/Yellow
Yellow--------------------------------- Yellow
Brown--------------------------------- Pink
Brown/White------------------------- Brown/White
Chocolate---------------------------- Chocolate
Dark Green--------------------------- Dark Green
(Sorry no picture for this side.)
That's everything. It took some trial and error but everything is sorted out with this setup. The low beam will stay on all the time. The hi-beam switch will add the hi-beam light and the low beam will stay on as well so for those of you running non stock headlights this may or may not be an issue. It will depend on the load being drawn if both lights are on. Anyhow, hope others go for this swap. It's kinda nice to have 13 year newer controls on my bike!
