need help please, my engine cuts out when i turn the lights

[j4y1985]

hi all i have a 1995 fzr 600r 4jh model, when i bought it it had been streetfightered, a week after i had it the fuel pump went, so i took off the tank to see bare wires everywhere, it was a rite bodge job, anyway i went and bought a new fuel pump, new harrness new switchgear, relays and fitted all onto my bike,

only problem i came up against was my ignition barrel had three wires(red yellow and blue) but on my harness i had a 2 wire plug (red and yellow) so i joined the colours, and i had another 4 wire plug(1 solid blue, and 3 blue/colours) so i put all them to the blue on my ignition, is that right?

my bike runs perfect now but it cuts the engine out whenever i turn my lights on, also there are to plugs on my harness that i cant find were they go, they have both got two wires a green and a black one, one lands under the tank and the other lands near the coils, any1 know what they are for,
thanks

[yamaha_george]

J,
sorry mate but you need to tell us where in the world you are, a'95 is not an FZR in the USA but a YZF600 and the specifications are different (the wiring will for sure as US law is different to UK law re:- lights etc.)

Put you LOCATION in your personal profile PLEASE then may be some one in your neck of the woods can help out with a wiring diagram for your model

In the mean time welcome to the Forum take a good look thro the WIKI which is our storage area for tech. Knowledge

Y-Geo.

[j4y1985]

hi mate, cheers, im in sheffield, england, and on my log book it just says yamaha , will a picture of the bike help?

[yamaha_george]

hi mate, cheers, im in sheffield, england, and on my log book it just says yamaha , will a picture of the bike help?

J,
I had a funny feeling you were a fellow Brit, you need to put the Sheffield UK bit in your personal profile, then where you are, months down the road, is a glance away.

a picture would help(the folks here love pictures ) my betting is it is a Foxeye 600 , where the headlights look like slanted eyes.

LOOKS LIKE This?


I looked already in the WIKI for a '95 wiring diagram and have not found one, so I will post and ask if any one has one they care to share.

In the mean time I suggest you get on ebay/amazon/ or go to Halfords for a Haynes manual for the bike. (that will have a wiring diagram in it .

Since you are going to have to "patch" your wiring to make it work properly I suggest you take a look at this site (who I use and am very satisfied with ) for professional wiring parts:-

http://www.kojaycat.com

They are an english company and they stock actual Japanese connectors or replacement plug/ sockets

If you are not sure about these parts drop me a PM

[DonTZ125]

What an absolute wreck! *shaking head*

The ignition switch on a Foxeye is a 4-pin - Red, Brown/bLue, bLue/Yellow, bLue/Black. I don't know if there are differences here between the UK or US model. Red is your hot wire coming from the VRR; it connects to Br/L to power your lights etc. L/B & L/Y are part of your safety switch system; L/B comes from the TCI box, connects to L/Y, which goes to the Neutral / Clutch / Stand safety switches to ground. By hooking everything together, you are probably putting +12v to the NCS pin that needs to be grounded for the TCI to allow spark, thus chopping the engine.

I was going to say one of the G/B connectors under your tank was for the fuel sending unit, but the '95 had an in-tank pump with a 3-pin connector.

It may be easier to buy an entire new (used, un-gefukt) harness...

[yamaha_george]

Don,
yeh you could say it sounds messy BUT nothing is impossible with bike wiring (having made them from scratch from yamaha manuals )

The main difference between US & UK is the fact the US model has the headlight permanently on and the UK headlight is manual selection.

Added to that mix the Owner did say he had changed switch gear so hopefully what he was sold is correct for the bike (having been mis-sold odd electrical bits on ebay in the past .

[j4y1985]

ive been on the net for age and just stubled across this ignition on ebay,
http://cgi.ebay.co.uk/IGNITION-SWITCH-Y ... 3caad4c8f1, do you think this will solve my problem, ? the ignition that is on my bike now only has for wires coming from it, but this one on ebay matches my colours on my new loom,

[j4y1985]

this is same as the ignition that i have now,
http://cgi.ebay.co.uk/IGNITION-SWITCH-Y ... 3cab31ab7c

[DonTZ125]

Ohhhhhhhh.... Ok, the light comes on. Some days my reading comprehension skills approach those of my 5yo daughter...

I caught the bit about new switches in your initial post, but I missed the part about a new harness. If the harness matches the TCat ignition tower, then I would suggest you bought youself a 97+ TCat harness. This would explain the two floating G/B connectors under the tank; the Foxeye had an in-tank pump with integral level sensor and a 3-pin plug, while the Thundercat has a separate in-tank sensor and an external pump, each with a 2-pin connector.

At this point you need to make a decision - do you want a '95 wiring system, or a '97? Some of the items are interchangeable, some are not. Mixing and matching will lead to confusion - the ignition barrel being a case in point. Gods help the poor bugger you ever sell this thing to!

If you have a '95 ignition switch and (presumably) a '95 TCI, '95 tank with pump and sensor, '95 head and tail ights, it may be better (if more annoying) to pull that '97 harness back off to sell, and find yourself a '95 harness.

[yamaha_george]

Ohhhhhhhh.... Ok, the light comes on. Some days my reading comprehension skills approach those of my 5yo daughter...

I caught the bit about new switches in your initial post, but I missed the part about a new harness. If the harness matches the TCat ignition tower, then I would suggest you bought youself a 97+ TCat harness. This would explain the two floating G/B connectors under the tank; the Foxeye had an in-tank pump with integral level sensor and a 3-pin plug, while the Thundercat has a separate in-tank sensor and an external pump, each with a 2-pin connector.

At this point you need to make a decision - do you want a '95 wiring system, or a '97? Some of the items are interchangeable, some are not. Mixing and matching will lead to confusion - the ignition barrel being a case in point. Gods help the poor bugger you ever sell this thing to!

If you have a '95 ignition switch and (presumably) a '95 TCI, '95 tank with pump and sensor, '95 head and tail ights, it may be better (if more annoying) to pull that '97 harness back off to sell, and find yourself a '95 harness.

Don & co.,
Both US & UK wiring diagrams are listed for the year so printouts will show the difference there is also a 97 wiring diagram I think (just had my med so still fuzzy )

I passed the link to the service manual to the backroom boys to upload (maybe) as it is 66Mb and beyond my resources as director

NOTE TO ALL:-
with any bike you mod/ service you should keep a Log book of what you do and what parts you replace with what .

That way a year down the line if you need to service it you know what you did that is not stock (maybe)
.
If you sell it you pass on the book that way yo do not get referred to on some Forum as that "idiot PO "

[DonTZ125]

Yeah, that '95 US wiring diagram is a Haynes or something, and is pretty horrid. I've noted several errors that don't match the parts fiche (single headlight, single taillight, discrete pump & fuel sensor w/ 2x 2-pin conx, etc).

I'm still trying to track down '95-96 manuals; they're pretty rare, as (obviously) they were only made for 2 years...