How to modify you stock headlight harness for a track/race only bike. - 600RR.net
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post #1 of 6 (permalink) Old 05-27-2012, 09:03 PM Thread Starter
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How to modify you stock headlight harness for a track/race only bike.

I got sick of dealing with all the extra crap on the front harness so I decided to clean it up. You can get one of these harnesses off Ebay for around $20 so it can be done without much worry about reversing it.
You’ll need a small flat head screw driver, electrical tap, a razor blade, a multimeter, and a wire cutter.
First take the harness off the bike

Use your razor knife to cut the sleeve off the harness. A portion of the harness is covered with a piece of rubber that’s wrapped around it under the tape. Be careful not to cut any of the wires underneath. You just have to the main harness run, not the pieces the run to the lights. I used small pieces of electrical tape every couple of inches just to hold it together.

Open the locks on the 33 pin connector using a small screw driver.

Using the multimeter, verify the wires that are to be removed by metering from the connector to the 33 pin connector. Then use the small screw driver and unlatch the lug from inside the connector.
You can pull all the wire EXCEPT the black/white wire attached to the position light. This wire also powers the dash.


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Last edited by 03WisconsinRR; 05-27-2012 at 09:11 PM.
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post #2 of 6 (permalink) Old 05-27-2012, 09:11 PM Thread Starter
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Start peeling the wires you removed out of the rest of the harness.
In the harness you’ll see a few splices that are wrapped in blue tape. Locate the splice for the black/white wires. This is the only cut you need to make. Cut the wire that goes to the position light leaving the wire that runs between the two connectors then wrap the lug back up with the tape.


Once you’ve pulled them all the way down to the black 20 pin connector open the latches on the connector.



08'RR
Akra Evo TI - Bazzaz ZfiTc - Acumen Gear Indicator - Yoyo Stay - Keyless Mod - Michelin Power Cup - HRC overflow - ECUnleashed
Yoyo Slipper - Galfer Lines - HRC Rear Res - HRC Throttle - Woodcraft Sliders - Woodcraft Rearsets - Servo Mod - Samco Hoses
BMC - Hotbodies - Brembo RCS19 - Penske 8987 & 20mm Valving - ASV Levers - Rk 520 - GPR Damper - EBC XC Rotors
Woodcraft Clipons - Gilles Chain Adjuster - R&R Subframe - PAIR Mod - Cox Rad Guard - MOYT 4 cell - Factory Pro Shift Star
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post #3 of 6 (permalink) Old 05-27-2012, 09:12 PM Thread Starter
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Using the small screw driver unlatch the lugs from the 20 pin connector. This can be kinda tricky. You need to stick the screwdriver in the T shaped hole then pivot the screwdriver in while pulling on the wire. It takes a few times to get it right.

Once you have all the wires removed you’ll be ready to tape it back together.

Using electrical tape wrap the entire length of the harness making sure you tape the rubber pieces back into the harness as strain relief like the stock harness had.

Now you’re ready to ready to plug it back in.

08'RR
Akra Evo TI - Bazzaz ZfiTc - Acumen Gear Indicator - Yoyo Stay - Keyless Mod - Michelin Power Cup - HRC overflow - ECUnleashed
Yoyo Slipper - Galfer Lines - HRC Rear Res - HRC Throttle - Woodcraft Sliders - Woodcraft Rearsets - Servo Mod - Samco Hoses
BMC - Hotbodies - Brembo RCS19 - Penske 8987 & 20mm Valving - ASV Levers - Rk 520 - GPR Damper - EBC XC Rotors
Woodcraft Clipons - Gilles Chain Adjuster - R&R Subframe - PAIR Mod - Cox Rad Guard - MOYT 4 cell - Factory Pro Shift Star
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post #4 of 6 (permalink) Old 05-28-2012, 02:08 PM Thread Starter
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Just a few more pictures. These are the wires removed from the 33 pin connector


And the 20 pin connector

08'RR
Akra Evo TI - Bazzaz ZfiTc - Acumen Gear Indicator - Yoyo Stay - Keyless Mod - Michelin Power Cup - HRC overflow - ECUnleashed
Yoyo Slipper - Galfer Lines - HRC Rear Res - HRC Throttle - Woodcraft Sliders - Woodcraft Rearsets - Servo Mod - Samco Hoses
BMC - Hotbodies - Brembo RCS19 - Penske 8987 & 20mm Valving - ASV Levers - Rk 520 - GPR Damper - EBC XC Rotors
Woodcraft Clipons - Gilles Chain Adjuster - R&R Subframe - PAIR Mod - Cox Rad Guard - MOYT 4 cell - Factory Pro Shift Star
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post #5 of 6 (permalink) Old 02-21-2014, 02:14 AM
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Thanks for the tip. will be applying it to our F2 sidecar. It is a pain and not necessary on a race bike. An excellent post. Cheers.
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post #6 of 6 (permalink) Old 05-21-2014, 11:47 AM
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I am currently looking into reducing wiring from the harness and would like to thank the OP for the info.

I have a few questions I am not sure about that maybe someone can help with, I have an aftermarket sub frame on my 07 and I would like to also reduce the wiring under the seat where possible.

I do not use the bike for road riding, track only and I am happy to remove wiring permanently, is it possible to almost make a hrc harness by simply removing wiring from an OEM harness?

Any help would be much appreciated, I cant find any how to`s
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