Trail Tech 3 way switch
Posted September 11, 2011 - 01:02 PM
Posted September 11, 2011 - 03:48 PM
You'll have to make either a solder splice, crimp splice, or someother splice to join two wires together. All connections I'm talking about will be on the factory headlight switch wiring harness.. NOT the bikes wiring harness. ONLY cut the wire you're working on, you should NEVER cut a black wire. And use some heatshrink if you're soldering, or electrical tape. Make sure you protect any exposed wires from abrasion by either wrapping everything in electrical tape or some kind of electrical tubing.
If I say attach on the connector side, then that means connect to the wire coming out of the connector. Obviously, if I say attach to the wiring harness side, then that means connect to the wire leading away from the connector.
If you've got a multimeter handy, then I'll also let you know what you should be reading on the display once the bike is up and running and you make the appropriate switch.
STEP 1: First take off your headlight mask to gain access to the headlight wiring harness.
STEP 2: You should see a 3 pole connector behind there which separates the headlight switch wiring from the main wiring harness, it will have a Yellow, Blue, and Black wire. Disconnect it, and that will be what you're working on.
STEP 3: On the headlight wiring harness, cut the Yellow wire as close to the 3 pole connector and splice that wire to the Red wire coming off your TT 3 position switch. That will be the power in to the switch. Connection is on the connector side of the wire. Multimeter will see 12vDC between that wire and ground.
STEP 4: On the headlight wiring harness, cut the Blue wire again as close to the 3 pole connector and splice the Blue wire from the TT switch. That will be the rear light power lead. Again on the connector side. Multimeter will see 12vDC at the tail light bulb and ground.
STEP 5: Connect the Green Wire on the TT switch to the blue wire which leads to the headlight bulb connector (cut in step 4). That will be the power for the low beam. Obviously that will be on the wiring side. Multimeter will see 12vDC between blue headlight connector and ground/frame, when headlight switch is in low setting.
NOTE : The original headlight switch should've fallen away/been disconnected by this point.
STEP 6: follow the two wires leaving your factory kill switch to a connector. Should be a Black and Black/White wire. Connect those two wires to the Black and White wires from the TT switch. Polarity doesn't matter, just make sure each one is connected.
Optional step: crimp on a female spade connector to a section of wire that will attach to the unused pole on the headlight, and attach that to the Yellow wire on the TT switch. That will give you highbeam power. Multimeter will see 12vDC between that wire and ground/frame when in high setting.
Now make sure everything is tidy behind the headlight mask with wiring. Use zapstraps to hold the wires together and make sure that when you rotate your bars either direction that nothing catches.
Have fun, pm if you've got any other questions.
Edited by rs25, September 11, 2011 - 04:38 PM.