500 Two-Stroke Tech

500cc GP-Replica Tech Forums

Search  FAQ  Register Login
It is currently Mon Oct 15, 2018 8:54 pm

All times are UTC - 4 hours [ DST ]




Post new topic Reply to topic  [ 24 posts ]  Go to page 1, 2  Next
Author Message
 Post subject: RZ500 vs RD500 vs RZV wiring harness
PostPosted: Sun Aug 20, 2017 10:51 am 
Offline

Joined: Wed Jul 12, 2017 3:34 pm
Posts: 71
Location: Virginia
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.

Top
 Profile  
Reply with quote  
 Post subject: Re: RZ500 vs RD500 wiring harness
PostPosted: Sun Aug 20, 2017 12:26 pm 
Offline
User avatar

Joined: Tue Jul 19, 2011 7:49 pm
Posts: 249
Location: Toulouse France
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.


Top
 Profile  
Reply with quote  
 Post subject: Re: RZ500 vs RD500 wiring harness
PostPosted: Sun Aug 20, 2017 1:45 pm 
Offline

Joined: Wed Jul 12, 2017 3:34 pm
Posts: 71
Location: Virginia
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......


Top
 Profile  
Reply with quote  
 Post subject: Re: RZ500 vs RD500 vs RZV wiring harness
PostPosted: Sun Aug 20, 2017 1:55 pm 
Offline

Joined: Wed Jul 12, 2017 3:34 pm
Posts: 71
Location: Virginia
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 .


Top
 Profile  
Reply with quote  
 Post subject: Re: RZ500 vs RD500 vs RZV wiring harness
PostPosted: Sun Aug 20, 2017 2:35 pm 
Offline
User avatar

Joined: Tue Jul 19, 2011 7:49 pm
Posts: 249
Location: Toulouse France
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.


Top
 Profile  
Reply with quote  
 Post subject: Re: RZ500 vs RD500 vs RZV wiring harness
PostPosted: Sun Aug 20, 2017 4:49 pm 
Offline

Joined: Wed Jul 12, 2017 3:34 pm
Posts: 71
Location: Virginia
Thanks Phil!


Top
 Profile  
Reply with quote  
 Post subject: Re: RZ500 vs RD500 vs RZV wiring harness
PostPosted: Sun Aug 20, 2017 5:44 pm 
Offline

Joined: Wed Jul 12, 2017 3:34 pm
Posts: 71
Location: Virginia
for the gauge and thermo unit... you are referring to the temperature gauge??


Top
 Profile  
Reply with quote  
 Post subject: Re: RZ500 vs RD500 vs RZV wiring harness
PostPosted: Sun Aug 20, 2017 5:47 pm 
Offline
User avatar

Joined: Tue Jul 19, 2011 7:49 pm
Posts: 249
Location: Toulouse France
Yes


Top
 Profile  
Reply with quote  
 Post subject: Re: RZ500 vs RD500 vs RZV wiring harness
PostPosted: Sun Aug 20, 2017 6:47 pm 
Offline

Joined: Wed Jul 12, 2017 3:34 pm
Posts: 71
Location: Virginia
so i need to connect the temperature gauge into the thermo unit?, the themo unit wires are blue and brown.


Top
 Profile  
Reply with quote  
 Post subject: Re: RZ500 vs RD500 vs RZV wiring harness
PostPosted: Sun Aug 20, 2017 6:54 pm 
Offline
User avatar

Joined: Tue Jul 19, 2011 7:49 pm
Posts: 249
Location: Toulouse France
That's it


Top
 Profile  
Reply with quote  
 Post subject: Re: RZ500 vs RD500 vs RZV wiring harness
PostPosted: Mon Aug 21, 2017 1:57 pm 
Offline

Joined: Wed Jul 12, 2017 3:34 pm
Posts: 71
Location: Virginia
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.


Top
 Profile  
Reply with quote  
 Post subject: Re: RZ500 vs RD500 vs RZV wiring harness
PostPosted: Mon Aug 21, 2017 2:47 pm 
Offline
User avatar

Joined: Tue Jul 19, 2011 7:49 pm
Posts: 249
Location: Toulouse France
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 ?


Top
 Profile  
Reply with quote  
 Post subject: Re: RZ500 vs RD500 vs RZV wiring harness
PostPosted: Mon Aug 21, 2017 4:05 pm 
Offline

Joined: Wed Jul 12, 2017 3:34 pm
Posts: 71
Location: Virginia
R/Y
BLACK
G/Y
G/R (2)
BLUE
BLUE/BLACK
BROWN
GREEN


Top
 Profile  
Reply with quote  
 Post subject: Re: RZ500 vs RD500 vs RZV wiring harness
PostPosted: Mon Aug 21, 2017 4:12 pm 
Offline

Joined: Wed Jul 12, 2017 3:34 pm
Posts: 71
Location: Virginia
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....


Top
 Profile  
Reply with quote  
 Post subject: Re: RZ500 vs RD500 vs RZV wiring harness
PostPosted: Mon Aug 21, 2017 4:47 pm 
Offline
User avatar

Joined: Tue Jul 19, 2011 7:49 pm
Posts: 249
Location: Toulouse France
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 ).


Top
 Profile  
Reply with quote  
Display posts from previous:  Sort by  
Post new topic Reply to topic  [ 24 posts ]  Go to page 1, 2  Next

All times are UTC - 4 hours [ DST ]


Who is online

Users browsing this forum: No registered users and 3 guests


You cannot post new topics in this forum
You cannot reply to topics in this forum
You cannot edit your posts in this forum
You cannot delete your posts in this forum
You cannot post attachments in this forum

Search for:
Jump to:  
Powered by phpBB © 2000, 2002, 2005, 2007 phpBB Group