TTR250 2002
Headlight, Tail Light and Instrument Illumination Switch Installation


 

This job is not as simple as you would think because the 3 light feeds are all separate
and spliced into the brown  +12v  supply in the main loom in 3 different locations.

I opened the main loom to find where each of the three lighting circuits join into the common power feed.
I chose to fit the new switch wires near the 9 pin connector under the petrol tank because it was central
and out of sight and I didn't want to alter the loom on the handle bar near the Hi / Lo switch.

If you only want to switch the headlight off then you only need to cut the light brown wire at the 9 pin connector under the tank and fit a switch.
If you want to switch off the tail and number plate light then cut the blue wire as shown in picture 4 and transfer it's power feed to the new switch.
If you want to switch off the instrument illumination then cut the blue wire as shown in pictures 2 & 3 and transfer it's power feed to the new switch.

NOTE :- This mod does not disable the brake light !



Headlight Connector Yellow - Hi Beam
Green - Lo Beam          Hi / Lo switch is fed by the Yellow/red wire from the 9 pin connector under the tank
Black - Earth                 on the LHS - this wire changes to light brown on the other side of the 9 pin connector.
Tail / Number Plate Light Light Blue - Tail & Number Plate lights - This blue wire is spliced into a Brown +12v feed - see picture 4.
Yellow - Brake
Black - Earth
Instrument Illumination Blue - +12v                    The blue is spliced into a Brown +12v feed -
Black - Earth                  Pictures 2 & 3 show where to find and open this wire


                 Images open in a new window


headlightcut.JPG (128038 bytes)

The feed to the Hi / Lo switch is the Yellow / red wire in the switch harness. It changes to light brown on the other side of the 9 pin connector. Cut this light brown wire. The wire coming out of the loom is the +12v power feed. The wire on the 9 pin connector side is where you can extend the instrument illumination wire and tail light wires to.

instrument1.JPG (75610 bytes)

This shows where to cut the blue wire that feeds the instrument illumination.


instrumentcut.JPG (30434 bytes)


Cut the blue instrument illumination wire here because it's too hard to get at where it is spliced into the brown power feed.
The cut wire on the left is the +12v feed from the brown - fit a female crimp connector (so that it can be rejoined easily later) and lay it back in the loom and tape it up. The wire on the right comes from the speedo illumination. Fit a male crimp connector here and extend it to reach the 9 pin connector and join it to the cut brown wire that comes from the 9 pin connector.


tail.JPG (73055 bytes)

This shows where to open the loom and cut the blue tail light wire. Fit a female crimp connector to the wire coming from the front and lay it back in the loom and tape it up. Fit a male crimp connector to the blue wire coming from the rear and extend it to reach the 9 pin connector and join it to the cut brown wire that comes from the 9 pin connector.

switchcable.JPG (104068 bytes)

This shows the 9 pin connector pushed through the frame to the RHS so that it is easier to get at. You can see that the tail and instrument wires have been extended to this point and joined to the cut brown wire that comes from the 9 pin male connector.

Also shows the new switch wires with crimp connectors fitted and plugged into the brown power feed.

switch1.JPG (52598 bytes)

This shows the new light switch soldered to the new switch wires.

switch2.JPG (60702 bytes)

This shows the new light switch  installed below the instruments.

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Copyright 2004