RZ500 vs RD500 vs RZV wiring harness

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thumper580
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RZ500 vs RD500 vs RZV wiring harness

#1 Post by thumper580 » Sun Aug 20, 2017 10:51 am

I spent several hours putting on my spare wiring harness on my RZ500.... Sadly, it must be an RZV harness because there was an extra 9 pin connector on the harness and did not have the 3 pin connector to the right side handle bar on/off switch.

The RD wiring harness is in great shape.... Is there a way to convert it to an RZ harness?? Everything plugs in except for the plugs mentioned above...

At least I got some practice exchanging wiring harnesses.... :smt013

I'd also be willing to trade the RZV harness for an RZ harness if there we any interested parties.

Curious if the harness can be made to work on the RZ...without to much cutting and splicing. Thanks.
Last edited by thumper580 on Sun Aug 20, 2017 1:50 pm, edited 1 time in total.

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phildu31
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Re: RZ500 vs RD500 wiring harness

#2 Post by phildu31 » Sun Aug 20, 2017 12:26 pm

Do you mean a 6 pin connector rather than 9 that goes to the right side handle bar ?
The only 9 pin connector on RD goes to the left side handle bar.

thumper580
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Re: RZ500 vs RD500 wiring harness

#3 Post by thumper580 » Sun Aug 20, 2017 1:45 pm

the difference is a three pin connector and the rzv has two nine pin blocks and there is one nine pin one the bike left.....

It appears my spare wiring harness is for an RZV......

thumper580
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Re: RZ500 vs RD500 vs RZV wiring harness

#4 Post by thumper580 » Sun Aug 20, 2017 1:55 pm

My right side handle bar has a three pin connector. black, green/yellow and a brown.. also a single red/white wire with a bullet connector .

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phildu31
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Re: RZ500 vs RD500 vs RZV wiring harness

#5 Post by phildu31 » Sun Aug 20, 2017 2:35 pm

Ok, I understand now.
RZV has a switch between water temperature and fuel gauge on right hand side that isn't on other versions.
RD and RZV have both a manual lights switch (ON-PO-OFF) on right hand side.
RD has a 6 pin connector : black, green/yellow and brown ( as yours ) for kill switch / brake switch + red/yellow, blue and blue/black for lights switch and also the single red/white wire ( 2nd wire of kill switch )
For RZV, on the 9 pin connector yo should have these 6 ones + 3 other wires : one from the gauge, one to thermo unit, and one to tank.
I don't have the wiring diagram for RZV, so I don't know what colours these should be, but on RD the thermo unit wire to the gauge is green/brown.

What you can do at least cost is this :
1) For kill switch and brake switch : Cut your 3 pin connector on old harness and connect it to the corresponding wires on RZV harness.
Don't forget the stand-alone red/white.
2) For lights connection : cut and connect the 3 wires together on RZV harness ( red/yellow, blue, blue/black ).
This will make lights permanently on.
3) For the gauge, you must cut and connect 2 of the 3 wires together : gauge and thermo unit.
It will be a test and try but most probably, thermo unit wire is green/brown.

Hope this helps.

thumper580
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Re: RZ500 vs RD500 vs RZV wiring harness

#6 Post by thumper580 » Sun Aug 20, 2017 4:49 pm

Thanks Phil!

thumper580
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Re: RZ500 vs RD500 vs RZV wiring harness

#7 Post by thumper580 » Sun Aug 20, 2017 5:44 pm

for the gauge and thermo unit... you are referring to the temperature gauge??

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phildu31
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Re: RZ500 vs RD500 vs RZV wiring harness

#8 Post by phildu31 » Sun Aug 20, 2017 5:47 pm

Yes

thumper580
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Re: RZ500 vs RD500 vs RZV wiring harness

#9 Post by thumper580 » Sun Aug 20, 2017 6:47 pm

so i need to connect the temperature gauge into the thermo unit?, the themo unit wires are blue and brown.

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phildu31
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Re: RZ500 vs RD500 vs RZV wiring harness

#10 Post by phildu31 » Sun Aug 20, 2017 6:54 pm

That's it

thumper580
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Re: RZ500 vs RD500 vs RZV wiring harness

#11 Post by thumper580 » Mon Aug 21, 2017 1:57 pm

one more question.. maybe two.
shouldn't the temperature gauge be connected to the thermostat? There should be a connection already in the harness from the thermo unit (thermostat) up to the temperature gauge.

When you mention the thermo unit do you mean thermostat? The thermo switch, next to the thermo unit controls the fan operation.

I want to clear before I start cutting. Thanks.

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phildu31
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Re: RZ500 vs RD500 vs RZV wiring harness

#12 Post by phildu31 » Mon Aug 21, 2017 2:47 pm

The thermo unit is a little resistor whose electrical resistance varies with temperature.
It is effectively screwed on the thermostat, but that are two different parts.
And yes, the thermo switch only drives the fan.
In RD and RZ, the thermo unit is wired to the temperature gauge, but in RZV temperature gauge is also used as a fuel gauge, so you have a switch on right handlebar.
You're right, it's better to be sure before cutting ....
So, just to chack, what are the colours of the 9 pin wires ?

thumper580
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Re: RZ500 vs RD500 vs RZV wiring harness

#13 Post by thumper580 » Mon Aug 21, 2017 4:05 pm

R/Y
BLACK
G/Y
G/R (2)
BLUE
BLUE/BLACK
BROWN
GREEN

thumper580
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Re: RZ500 vs RD500 vs RZV wiring harness

#14 Post by thumper580 » Mon Aug 21, 2017 4:12 pm

Phil....I ran 12v from the thermo unit connector (rzv harness) to see if it ran through the main harness up to the temperature gauge plug in.... it did not. It ran to one of the green/red wires in the 9 pin connector we are discussing....

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phildu31
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Re: RZ500 vs RD500 vs RZV wiring harness

#15 Post by phildu31 » Mon Aug 21, 2017 4:47 pm

R/Y -> +12V from head fuse
BLACK -> Ground
G/Y -> to brake light
G/R (2)
BLUE -> to auxiliary light
BLUE/BLACK -> to lights switch
BROWN -> +12V from signal fuse
GREEN

So one of the green/red comes from thermo unit.
Logically, the other green/red will come from the tank ( for fuel gauge function ) : there should be a separate connector near the tank area ( 1 pin or 2 pins with ground ) corresponding to it.
And the last green would go to the temperature gauge plug : there are two 6 pin connectors that go to the meter assembly. You should find your green wire on one of them. Compare with your old harness to identify it ( same position as the green/red on old harness ).

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