Aftermarket Lights and Stock Looking Switches..

[AVGeek]

This is easily the most expensive forum I've been on! Thanks to Jaxon's group buy, I have a Baja Designs OnX light bar on the way. Well, I don't want to clutter up the handlebars with all kinds of switches, so thanks to the other threads here, I ordered a Kawasaki Versys LH switch cluster (same as the Euro ST cluster) and the 2013 FJR RH switch cluster. Both clusters include hazard buttons, so the plan as it stands right now is:

Wire up the FJR right cluster hazard switch to handle hazard light duties. I will be setting these up to be operable without the key.

The Versys left cluster hazard switch will be reserved for future use (I want to also mount a pair of BD SII lights on Jaxon's handlebar mounts). The Flash to Pass button will be wired in place of the momentary switch on the BD harness, to allow for switching between high, low and strobe modes. I still need to figure out the high beam trigger with the BD harness, I might need to create a momentary relay...

For now, I'm waiting for parts to arrive. I'll document the install as I get to it; June is a bit busy, so I don't know if I'll get it done before I leave for Colorado.

 

[Bigbore4]

FYI the hazzard switch in the left cluster is internally connected across the turn signal switch. It is will work without further wiring as soon as you wire in the switch.

 

[AVGeek]

FYI the hazzard switch in the left cluster is internally connected across the turn signal switch. It is will work without further wiring as soon as you wire in the switch.

Good to know, I will have to modify that to accomplish what I have in mind...

 

[tpak]

This is easily the most expensive forum I've been on! Thanks to Jaxon's group buy, I have a Baja Designs OnX light bar on the way. Well, I don't want to clutter up the handlebars with all kinds of switches, so thanks to the other threads here, I ordered a Kawasaki Versys LH switch cluster (same as the Euro ST cluster) and the 2013 FJR RH switch cluster. Both clusters include hazard buttons, so the plan as it stands right now is:

Wire up the FJR right cluster hazard switch to handle hazard light duties. I will be setting these up to be operable without the key.

The Versys left cluster hazard switch will be reserved for future use (I want to also mount a pair of BD SII lights on Jaxon's handlebar mounts). The Flash to Pass button will be wired in place of the momentary switch on the BD harness, to allow for switching between high, low and strobe modes. I still need to figure out the high beam trigger with the BD harness, I might need to create a momentary relay...

For now, I'm waiting for parts to arrive. I'll document the install as I get to it; June is a bit busy, so I don't know if I'll get it done before I leave for Colorado.

Would you kindly post up part numbers for those switch clusters?
Thanks

 

[AVGeek]

I ordered from Bike Bandit so these are their part numbers:

LH Cluster (Versys) 2403007
RH CLuster (2103 FJR) 3154058

 

[EricV]

What you need to use the momentary switch for on/off is a latching relay. I'll post some links and part numbers tomorrow. It's covered in my thread about using the FJR left side switch cluster for CC, etc.

I'm still having some fun with wiring on that task.

 

[AVGeek]

What you need to use the momentary switch for on/off is a latching relay. I'll post some links and part numbers tomorrow. It's covered in my thread about using the FJR left side switch cluster for CC, etc.

I'm still having some fun with wiring on that task.

I bet, that cluster is the most complex one I've seen! Since I am not (currently) planning on adding the Rostra, I decided the Versys style would be a better choice. And Bike Bandit got them shipped out yesterday, so they should be here early next week ::012::

 

[offcamber]

Is there a write somewhere on wiring the Versys cluster into the Teneres harness??

 

[AVGeek]

Is there a write somewhere on wiring the Versys cluster into the Teneres harness??

I think it was somewhere in this thread that mentioned it :http://www.yamahasupertenere.com/index.php?topic=2302.0. I will be documenting my install here for posterity...

 

[AVGeek]

So after a bit of delay in shipping the switches (the Versys cluster was backordered), and moving thrown in the mix, I got my garage setup today and managed to tackle the Versys switch cluster to see what I was dealing with.

Stock Kawasaki Plug:

Clutch Switch Plug

I started by pulling the pins from the plug, then realized I wasn't going to be reusing the pins, so simply cut the remainder off

Ultimately, this is what I was after:

The Pass Switch ties to the high beam switch wires in the harness. The hazard switch ties to the turn signal switch in the harness as well. Since I have other plans for these two switches, this wiring will be bypassed. To simplify the installation as well, my plan is to swap over the stock Tenere switches to the Versys housing (I still need to pull the ST housing to confirm I can do this, should be doing that this Sunday!); this way I have no need to modify the stock harness, and I will create a secondary harness for the two new switches.

Stay tuned, I might have my BD OnX light bar up and working for Colorado!

For the FJR cluster on the right, I plan on following Snakebitten's write up in this thread: http://www.yamahasupertenere.com/index.php?topic=7470.0

 

[patrickg450]

Did I miss it...........


are you going to be able to simply plug and play the new cluster so you will have hazards? I am thinking about doing this as well but got a few other more pressing issues first. I am not sure what all was involved in doing it. What are the costs for the clusters?

PG

 

[AVGeek]

Did I miss it...........


are you going to be able to simply plug and play the new cluster so you will have hazards? I am thinking about doing this as well but got a few other more pressing issues first. I am not sure what all was involved in doing it. What are the costs for the clusters?

PG

The Versys cluster is not plug and play, the FJR cluster almost is. I will be using the hazard switch on the FJR cluster, but I will be wiring them to be active without the key in the ignition. The hazard switch on the Versys cluster will be used to switch an additional set of lights I'll be adding in the future.

With my AMA discount, I bought the clusters from Bike Bandit for about $160 shipped.

 

[patrickg450]

OK got ya, I was guess there would need to be a relay added for the hazards.

 

[AVGeek]

OK got ya, I was guess there would need to be a relay added for the hazards.

If you just wanted to add hazards, and use them with the key switch on, you could use the Versys cluster, as the hazard switch is jumped to the turn signal switch, no relay necessary.

 

[patrickg450]

nice, thanks for the heads up. Ordered my new front tire, oil filter and what not............this my be my next project.


Thanks man ::012::

 

[AVGeek]

I'll knock out the full write-up tomorrow, but IT WORKS! I have both switch clusters installed, with the FTP button toggling the modes on the OnX Light Bar, and the hazard button on the FJR cluster switching on the flashers, without the key!

 

[snakebitten]

I'll knock out the full write-up tomorrow, but IT WORKS! I have both switch clusters installed, with the FTP button toggling the modes on the OnX Light Bar, and the hazard button on the FJR cluster switching on the flashers, without the key!

Excellent!

I still have the FJR hazard as switched hazards. (simply a bridge connection between left\right turn signals)
Looking forward to your write-up.

 

[AVGeek]

So thanks to this forum, especially snakebitten and Eric, I now have the switches installed and fully operational.

For the FJR cluster, I used SB’s excellent write up here:

http://www.yamahasupertenere.com/index.php?topic=7470.0

One thing to keep in mind is that the brake light circuit wires need to be pulled from the Tenere harness and reused. After I pulled them out, I used the stock sheathing from the ST harness to cover and protect these wires.

For unswitched hazards, I used Method #1 here:

http://www.motorcycleproject.com/motorcycle/text/hazards.html

I have an EB PC-8 fuse block, so I simply pulled a wire from circuit #8, which ran through the switch, then to the flasher and on to the taps to the indicator wires. To make sure I grabbed the right ones, Behmer’s post HERE was key. The dark green and dark brown wires are for the indicators; there are light brown wires in the same harness.

I realize I forgot to take pictures of this part, so if you want to see anything specific, let me know. It will be a bit before I can get them though, as I am leaving for a business trip, and will be getting back right before the rally.

But here is the switch mounted up, ready for action:

Now for the fun part, the LH pod install. If you didn’t see my earlier posts, I wanted the Pass button to control the Baja Designs OnX Light Bar (replacing the switch provided with the harness), and the hazard switch will be used for additional lights in the future (I am looking at the Baja Designs SII lights mounted on Jaxon’s handlebar mounts). Because of this, the easiest way to do this was to swap in the stock switches from the Tenere, and use the additional switches wiring separately.

The front side of the two switch clusters are nearly identical. The Tenere has an additional screw boss for a piece of plastic whose purpose I can’t figure out.

The horn button goes in first, followed by the turn signal switch and the high/low beam switch.

Here you can see the back half of the new cluster and the wiring harness (with stock sheathing re-used):

And here it is mounted up and ready to go:

And here is the light bar mounted up:

The harness drops back behind the radiator scoop:

To make routing the wiring easier, I removed the windshield, and headlights, and tied up all wiring along factory routes. I used the full Baja Designs harness, mounting the on-off switch on the left hand windshield stay (where a lot of people mount a Powerlet outlet). I used a short sheet metal screw to attach the relay near the rectifier (behind the fuse block) and ran the mains wire from a switched circuit on the EB PC-8. Altogether, the install took me about 4-5 hours (not counting a quick run to Radio Shack and Autozone for the hazard parts I needed!).

 

[Techonly]

I did install a aux light switch on the left side and wire the "kill switch" to flash all lights (aux and hi-beam). Work great and looks like it comes with the bike...easy to reach with my tump 8)

 

[AVGeek]

Quick update. While I was at the Rally, I found my horn wasn't working. A it turns out, the casting in the Versys cluster is different enough for the horn button that it wasn't fully engaging. I took my Dremel and ground off the tab on the stock ST switch, and now have horns working normally.