replacing left switches...wiring issues

[yamaha_george]

I had to put my notes somewhere where i can go to them later, thought i would share it with you guys

*double checked switch wiring (for the 4th time) - OK
*turned right turn signal on through switches, headlight not on, turn signal light shining on gauge cluster and not blinking, right rear signal blinks bright then dim, front does not blink.
*turned left turn signal on through switches, headlight not on, turn signal light shining on gauge cluster and not blinking, front left and rear left signal works perfectly.
*swapped front right and left turn signal, both signals work fine
*removed switch
*jumped connections on the harness to simulate headlight low beam - no headlight, gauge turn signal light stays on
*disconnected jumper on headlight
*jumped connections on the harness to simulate left turn signal w/o right front signal plugged in - all lights blink
*jumped connections on the harness to simulate left turn signal w/ right front signal plugged in - all lights blink except right front
*jumped connections on the harness to simulate right turn signal w/o right front signal plugged in - no lights blink

looks like there's a crossed wire for headlight low beam, possibly green (headlight low beam) and dark green (right turn signal)

now i've gotta find it

Sounds as thought the rh Front has something HINKY about it

[SilverJS]

Hey Match,

Any progress on this? I've got YZF controls (from my previous YZF install) that I want to adapt to an FZR600 harness, and that's the last thing I need to do. If that doesn't work, I'll either get 05 R6 ones or FZR ones, but that would keep me off the road for another two weeks...=(((

BTW, what years YZF are you talking about? And FZR, for that matter?

Cheers!

[match417]

yeah, i bought a box of cheap butt connectors, that was part of my problem, they didn't crimp right. Also had a damaged wire on the front right turn signal causing problems. It's a little easier if you take out the stock turn signal relay and just wire in a cheap one from napa and wire it in to the system. I didn't have a way to wire the autocancel wire in from the relay because of the differences between the two turn signal systems, so i wired it to ground. I'll have to look at my bike again and see which wire i used to control the blinking, then let you know which wire I used for the turn signal. That's the one that you wire in to the turn signal relay. Give me a couple days, i might have some time tomorrow to open up the bike again, same thing goes for sunday. If none of those days then i know i'll be taking it apart monday night.

Let me know if i didn't answer your question or if you have anything else to ask. I don't mind helping you out with it.

[SilverJS]

OK. Here's my contribution to this. I have adapted 1998 YZF600 controls to fit a 1996 FZR600 wiring harness. I'll type this up right now as I have litterally JUST completed this (I have the laptop in the garage with me to check wiring diagrams, threads and such - haha!) and I have the bike right in front of me so I can reference it. Here's how I did it.

Right control :

FZR Red/Yellow into FZR Blue/Black (for headlights - as per the 05 R6 controls how-to, this is because the FZR had an auto-headlight-off feature when pressing the start button. Newer controls don't have that, so we just bypass that function and connect those wires, which power the headlights, together);
The rest, as hinted at earlier in this thread, are the very same colours, EXCEPT the red wires. I can't be sure if what I've done here totally works, so I'll update when I actually fire up the bike. As I have it, it's just as per the 05 R6 control swap write-up, and that was based on my poring over both wiring diagrams. I hope I have it right!

Left control :

Chocolate, Dark Green, Yellow, Green, Black/Yellow, Blue/Yellow, Brown/White, Black : Same to Same;
FZR Yellow/Red : To Ground (I just twisted up the FZR Yellow/Red and Black together and crimped them in the same connector with the YZF black);
FZR Blue/Black to YZF Red/Yellow;

That leaves one wire on the YZF cluster : Brown, the horn switch. This was a pain to troubleshoot, but what I've finally got is this :

Connect the YZF's separate two horn connectors (on Black/White and Black, in their own pigtail FROM THE SWITCH) to the horn. Then, find any power wire (I actually used the Brown from the right control), splice into it and send THAT to the YZF's brown wire. You can now safely ignore the FZR's pink wire and the FZR's two horn connectors further up front in the harness.

With this setup, EVERYTHING works perfectly.

Hope this helps - I'll update with the red wires in the right control as I get more info.

Cheers!