this post was submitted on 04 May 2025
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I'm trying to install zero-rise clip-ons, because I find that more comfortable for riding at speed than sitting upright. But the instrument cluster and headlight assembly interfere with using clip-ons, so I need to replace the headlight assembly, and relocate the instrument cluster.

Photos are uploaded on Imgur, because they were too large for Lemmy.

First part:

I'm trying to figure out what the individual wires are that are going into the terminal for the headlight assembly. There are a total of five wires in a six-pin connector (with the last terminal plugged off): blue with red stripe (UR), solid yellow (Y), solid black (B), blue with white stripe (UW), and blue with yellow stripe (?UY?).

When I look at the wiring diagram in the service manual, black (B), blue/white (UW), and blue/red (UR) go to the headlamps, and black (B) and yellow (Y) go to position lights, and I don't see anything, anywhere on the diagram labeled blue/yellow.

So, first, which wire does what? I assume that two are low beams/DRLs, two are high beams, black is the neutral (?). If I trace the wiring diagram, the blue/red comes from the headlamp dip switch, so I think blue/red is the high beam, and blue/white is the low beam/DRLs? Black seems to go to everything, so I'm assuming that's neutral.

...But what the hell are the position lights, and what it the blue/yellow wire for?

Second part:

Does anyone know exactly what the connector is that I need here? It looks like it's a Sumitomo DL 090 Sealed Series 6195-0024; does that seem correct?

Third part:

If I'm trying to wire in a 7" JW Speaker LED adaptive headlamp. Since that's only one headlamp, but the existing wiring harness wants to have two high beam wires, and two low beam wires, will I want to splice another wire into the high beam and low beam on the before crimping on terminal ends? And what about that pesky position light? Will that be the red wire--front position--for the JW Speaker headlamp?

...And I still have no idea what that blue/yellow wire does.

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[–] [email protected] 2 points 2 weeks ago

Is there no other running light in the stock headlight cluster, then? For instance, my FZ has the "jewel" thing above the headlight which is separate from the headlight/low beam, but it's still always on when the engine is running.

Regardless of where it goes, the position light is a running light, on when the bike is running. It might also be one of those Euro/US things where some countries got the option and some didn't, but the harness is the same. (E.g., the 1s gen KLR's have the "city lights" connector on the US models for a set of running lights that were not installed on US market bikes.)