This is something I've been planning since I got my '83. It took some studying of the various wiring diagrams but I figured it out. I wanted to try to do this without having to run a bunch of extra wires, utilizing as much of the existing wiring as possible. All I ended up having to add was 3 small jumper wires. This is going to take several posts to explain it all so bear with me, lol.
The first big hurtle is getting headlight power up into the bucket so it can be connected to the "new" switch. On the stock bike, it doesn't go there. It runs from the headlight fuse to the headlight safety relay, then to the RLU, and finally up to the bucket. I actually want to eliminate the headlight power connection to the safety relay to get rid of the "auto-on" feature.
The '81 and later models have a clutch safety switch and relay. Since I had removed them, I was able to tap into a now unused wire in the relay plug to get the headlight power up into the bucket. It's location right next to the starter/headlight safety relay meant just a short jumper wire was required .....
The clutch relay plug has 4 wires running into it. Two are red/whites, power in and out to the solenoid. On mine, these have already been jumpered together to restore solenoid power and starter function. The other two are the "triggers" for the relay. One is a light blue from the neutral light, the other is a black/yellow from the clutch switch up on the lever. This is the one to tie into to get headlight power up into the bucket. So, a short jumper wire was made .....
Headlight power comes into the safety relay on a red/yellow wire. That wire running into the safety relay was pulled out of the plug and the jumper wire fitted in it's place. The other end of the jumper wire connects to the black/yellow in the clutch relay plug .....
And here's the completed "jump". The end of the red/yellow wire removed from the safety relay has been covered with shrink wrap and tucked out of the way. All in all, a pretty easy and neat looking change .....
The first big hurtle is getting headlight power up into the bucket so it can be connected to the "new" switch. On the stock bike, it doesn't go there. It runs from the headlight fuse to the headlight safety relay, then to the RLU, and finally up to the bucket. I actually want to eliminate the headlight power connection to the safety relay to get rid of the "auto-on" feature.
The '81 and later models have a clutch safety switch and relay. Since I had removed them, I was able to tap into a now unused wire in the relay plug to get the headlight power up into the bucket. It's location right next to the starter/headlight safety relay meant just a short jumper wire was required .....
The clutch relay plug has 4 wires running into it. Two are red/whites, power in and out to the solenoid. On mine, these have already been jumpered together to restore solenoid power and starter function. The other two are the "triggers" for the relay. One is a light blue from the neutral light, the other is a black/yellow from the clutch switch up on the lever. This is the one to tie into to get headlight power up into the bucket. So, a short jumper wire was made .....
Headlight power comes into the safety relay on a red/yellow wire. That wire running into the safety relay was pulled out of the plug and the jumper wire fitted in it's place. The other end of the jumper wire connects to the black/yellow in the clutch relay plug .....
And here's the completed "jump". The end of the red/yellow wire removed from the safety relay has been covered with shrink wrap and tucked out of the way. All in all, a pretty easy and neat looking change .....