05-27-2010, 08:23 PM
Toggle ignition write up for 03-08 Kawi's.. possibly 09-10's as well...
Items required:
Wire cutters/strippers
Old/current ignition(ignition base)
Soldering Iron and solder
Electrical Tape
18 guage wire(spare wire for extra length for toggle switch relocation)
2 Pole 20 amp Toggle Switch (preferably metal)
If old/current ignition is destroyed find replacement resistor, consult wiring diagrams
This is strictly to wire the ignition! Not for additional parts such as headlights, taillights, etc that is based off the wiring harness!!!
Begin by getting all items required, finding a good location for toggle switch(preferably not somewhere easily kicked, hit, touched but also not somewhere so hard to access that it is hard to reach in the event of something happening ie.. kill switch failure) I have mine located on the clutch side, I need to move it over to the throttle side.
Desolder the resistor from the base of the ignition.
Cut the ignition base off of the harness(as seen above)... There is another harness connection at the other end of the ignition base harness to connect it to the main harness.(pictured below)
Identify the GREY, WHITE, and BROWN wires. These are the wires needed for the ignition and back to the computer.
I aplogize in advance.. the pics may confuse some because the spare wire that I used to lengthen the pigtail was white.. so all the wires leading to my switch are white, but you can see how and what wires are connected in the pics.
Strip and prep the WHITE, BROWN, and GREY wires.
Also a jumper piece of wire is required approxiametly 6inches or less, prep both ends by stripping.
Attach one end of jumper wire to the BROWN wire via solder or electrical tape or other means. Attach the other end of the jumper wire to the resistor via solder. Now attach the second end of the resistor to the GREY wire, thus completing a loop between the BROWN and GREY wires. (picutred below)
(Sorry I didnt remove the tape covering the resistor between the GREY and white jumper wire but its there)
Attach the WHITE wire to one pole on the switch. This is your hot wire (power)
Attach the BROWN wire and the JUMPER wire to the other pole on the switch.
If wiring does not reach simply extend the wires by adding more length. If this is required, solder in a 3rd wire at the junction between the BROWN and JUMPER wires(pictured above and below)
After all connections have been made, tape everything up nice and tight.
Fasten wires to switch as stated above in desired location.
Test to make sure everything is functioning as it should. Ex. Computer powering on, fuel pump priming.
Hide all wires and connections and hope it works for you.
Items required:
Wire cutters/strippers
Old/current ignition(ignition base)
Soldering Iron and solder
Electrical Tape
18 guage wire(spare wire for extra length for toggle switch relocation)
2 Pole 20 amp Toggle Switch (preferably metal)
If old/current ignition is destroyed find replacement resistor, consult wiring diagrams
This is strictly to wire the ignition! Not for additional parts such as headlights, taillights, etc that is based off the wiring harness!!!
Begin by getting all items required, finding a good location for toggle switch(preferably not somewhere easily kicked, hit, touched but also not somewhere so hard to access that it is hard to reach in the event of something happening ie.. kill switch failure) I have mine located on the clutch side, I need to move it over to the throttle side.
Desolder the resistor from the base of the ignition.
Cut the ignition base off of the harness(as seen above)... There is another harness connection at the other end of the ignition base harness to connect it to the main harness.(pictured below)
Identify the GREY, WHITE, and BROWN wires. These are the wires needed for the ignition and back to the computer.
I aplogize in advance.. the pics may confuse some because the spare wire that I used to lengthen the pigtail was white.. so all the wires leading to my switch are white, but you can see how and what wires are connected in the pics.
Strip and prep the WHITE, BROWN, and GREY wires.
Also a jumper piece of wire is required approxiametly 6inches or less, prep both ends by stripping.
Attach one end of jumper wire to the BROWN wire via solder or electrical tape or other means. Attach the other end of the jumper wire to the resistor via solder. Now attach the second end of the resistor to the GREY wire, thus completing a loop between the BROWN and GREY wires. (picutred below)
(Sorry I didnt remove the tape covering the resistor between the GREY and white jumper wire but its there)
Attach the WHITE wire to one pole on the switch. This is your hot wire (power)
Attach the BROWN wire and the JUMPER wire to the other pole on the switch.
If wiring does not reach simply extend the wires by adding more length. If this is required, solder in a 3rd wire at the junction between the BROWN and JUMPER wires(pictured above and below)
After all connections have been made, tape everything up nice and tight.
Fasten wires to switch as stated above in desired location.
Test to make sure everything is functioning as it should. Ex. Computer powering on, fuel pump priming.
Hide all wires and connections and hope it works for you.