Ignition wires
 

Hey all. I'm traveling through the States on an XT600e 4PT. I've had to replace the ignition due to someone screw drivering the old one. The original wires were:

Red - live
Brown - return
Blue
blue/red
blue/yellow
blue/black

The replacement part looks generic and has almost the same wires, but they are:

Red
Brown
Blue
Blue/red
Black
Black/white

I connected them all colour to colour, exept for the blacks, which swopped and connected with blue/yellow and blue/black. Either way the bike starter went, but it wouldnt fire up. All the lights and indicators are working and the neutral light comes on. I have bridged out the clutch switch and the sidestand switch already. Anyone know the connections for the wires?:helpsmilie:

Found out that the new ignition switch has three distinct pairs, the red & brown are normally open, but close when the ignition is on. The blue/red & blue pair also close when the ignition is turned on. The black & black/white pair are normally closed and open when the ignition is on. I cannot compare these to the old one, as it is jammed, but i've managed to get the bike started, the same as it was when it was hot wired, but the tail light does not come on. I think that the original ignition had a triple connection when it was switched to the on position, so this new one is missing one connection. I probably need to bridge it, but I'm keen to here from anyone who has experience in this, as a mistake could be costly.

Have you tried removing the electrical connector from the old key switch and fitting it to the new? I've done this when I had the electrics fail and wanted to keep the original key...

Hi there

The three pairs which are connected together in the on position are:

red and brown
blue and blue/red
blue/yellow and blue/black

In the park position the only connection is red and blue/red which switches the side lights on.

If you can't get the tail light to work I'd start looking at some mistake in the position of the blue/red connection.

Another plan may be to double up the blue with the blue/yellow and the blue/red with the blue/black so that you can use your new switch without too much messing.

Here is a link to a page where you can download the service manual, the wiring diagram for the whole bike is on p345 (last but one page). The language is Portuguse but you can easily work out the colours with a little spanish. The links are in the stickies at the top of the Yamaha tech thread.

http://www.xt600.com.br/manuais/servico4MW.zip

Hope you get it sorted - Alastair.