chapter 3 body electrical.pdf · c headlight adjustment headlights may be adjusted for both...

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CHAPTER 3

BODY ELECTRICAL

Headlight Adjustment, Bulb Replacement ................ . .......... . ....... 3.1-3.3

Electrical Test Equipment, Digital Multitester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3.3

Headlight Bulb Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3.4

Lighting System Test, Unregulated and Regulated. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3.4

Seat Harness Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5

Hi/Low Switch Testing ........... . ...... . ............. . ...................... 3.5

Ignition Switch Testing

Non Battery Models .......... . . .......... ............ . ............... 3.5

Electric Start and Fuel Injected ...... ... .......... . ...... ........ . ... . . 3.6

Speed Control Assurance Testing ........................... . .............. 3.7-3.8

Coolant Temperature Hot Light ......... . ........ . ............... . .......... .. 3.9

HandlebarlThumbwarmers ....... . .. .. .. ...... ..... ... ...... ....... . .... 3.10-3.11

Wiring Diagram/Schematics

1985 - Star - 1 00 Watt Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3.12

1985 - SS, Long Track - 120 Watt Alternator .......................... . . . . ..... 3.13

1985 -Indy Trail- 120 Watt Alternator ........ .. .............................. 3.14

1985 - Indy 440 - 120 Watt Alternator . .... .. .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15

1985 - Indy 600, Indy 600 SE - 120 Watt Alternator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16

1986 - Star - 100 Watt Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3.17

1986 - Sprint, SS, Long Track - 120 Watt Alternator .. ........................... 3.18

1986 - Indy Trail - 120 Watt Alternator . .................................. . .. . . 3.19

1986 - Indy 400 - 120 Watt Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.20

1986 - Indy 600, Indy 600 SE - 120 Watt Alternator .......... . . . . ............... 3.21

1987 - Star, StarTrak - 100 Watt Alternator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.22

1987 - Sprint, LongTrack (RLR) - 120 Watt Alternator .... .. .. ................... 3.23

1988 - Indy Sport, Indy Trail (133 SKS) - 120 Watt Alternator .... . ............... 3.24

1988 - Indy 400 (133 SKS), Indy 600 - 120 Watt Alternator ...................... 3.25

1988 - Star, StarTrak - 100 Watt Alternator ....... . . .. .......... .... . . . .. .. .. . . 3.26

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1988 - Sprint, LongTrak (RLR) - 120 Watt Alternator ........... . ................ 3.27

1988 - Indy Sport, Indy Trail (All Except ES) - 120 Watt Alternator ................ 3.28

1988 - Indy 400 Classic - 120 Watt Alternator ............. ... . ................. 3.29

1988 - Indy 400 (SKS), Indy 650 (SKS) - 120 Watt Alternator ........ ... .... . .... 3.30

1989 - Star, StarTrak - 100 Watt Alternator .................................... 3.31

1989 - Sprint ES, LongTrak (LTR) -120 Watt Alternator ......................... 3.32

1989 - Sport, Sport GT - 120 Watt Alternator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3.33

1989 - Indy 400, 500, 500 SP - 120 Watt Alternator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.34

1989 - Indy 500 Classic - 120 Watt Alternator .. .. ................. . ...... . . . . .. 3.35

1989 -Indy Trail ES, SP, SKS, Deluxe, SuperTrak - 120 Watt Alternator ........... 3.36

1989 - Indy 650 (SKS) - 120 Watt Alternator . . ................................. 3.37

1990 - Star, StarTrak - 150 Watt Alternator .......................... .......... 3.38

1990 - Sprint ES - 150 Watt Alternator . ....................................... 3.39

1990 - Indy Sport, Sport GT - 150 Watt Alternator .................. . ........... 3.40

1990 - Indy WideTrak - 200 Watt Alternator . .... ............................... 3.41

1990 - Indy Trail, Deluxe - 200 Watt Alternator ............... . ................. 3.42

1990 - Indy 400, 500, 500 SP, SKS - 200 Watt Alternator .......... .. . ........... 3.43

1990 - Indy 500 Classic - 200 Watt Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3.44

1990 - Indy 650, SKS - 120 Watt Alternator ..... ....... ........................ 3.45

1991 - StarLite, Indy Lite - 150 Watt Alternator ................................. 3.46

1991 - Indy Sport, Sport GT - 200 Watt Alternator .. ... ............... . ......... 3.47

1991 - Indy WideTrak - 200 Watt Alternator .................................... 3.48

1991 - Indy Trail, Deluxe, SuperTrak - 200 Watt Alternator ....................... 3.49

1991 - Indy 400, 500, 500 SP, SKS - 200 Watt Alternator ........................ 3.50

1991 - Indy 500 Classic - 200 Watt Alternator . . .................. . .. . .......... 3.51

1990-1991 - Indy RXL ................. . .................................... 3.52

1991 - Indy 650 - 180 Watt Alternator ......................................... 3.53

1992 - Star Lite, Indy Lite, Lite GT - 150 Watt Alternator . . . . . . . . . . . . . . . . . . . . . . . .. 3.54

1992 - Lite Deluxe - 150 Watt Alternator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3.55

1992 - Indy Sport, Sport GT - 200 Watt Alternator . . .... . ............. ... ....... 3.56

1992 - Indy Trail, Trail Deluxe, SuperTrak - 200 Watt Alternator .. ............. . .. 3.57

1992 - Indy 440, 500 - 200 Watt Alternator .. .. ................................ 3.58

1992 - Indy 440 XCR - 200 Watt Alternator ............................. ...... . 3.59

1992 - Indy 500 SP, SKS - 200 Watt Alternator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3.60

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1992 -Indy 500 Classic - 200 Watt Alternator ..... . ..................... . ... . . . 3.61

1992 - Indy Wide Trak - 200 Watt Alternator . .. ................................. 3.62

1992 - Indy 650 - 180 Watt Alternator . . . .. ............ . .. . ....... . .. ... . ..... . 3.63

1992 - Indy RXL, SKS - 180 Watt Alternator ................................... 3.64

1993 - Indy StarLite/GT, Lite/GT - 150 Watt Alternator. . . . . . . . . . . . . . . . . . . . . . . . . . . 3.65

1993 - Indy Lite Deluxe - 150 Watt Alternator ............ . .... .. ............... 3.66

1993 - Indy Sport - 200 Watt Alternator ............ . .......... ... ........ .... . 3.67

1993 - Indy Trail, Trail Deluxe - 200 Watt Alternator .. . . . .. . .... . ......... ...... , 3.68

1993 - Indy 440, SKS - 200 Watt Alternator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.69

1993 - Indy 440 XCR - 200 Watt Alternator ....... . ............ . . . . . . .... . .. .. . 3.70

1993 - Indy 500 EFI, SKS - 200 Watt Alternator ................... .. ... ........ 3.71

1993 - I ndy Classic - 200 Watt Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3.72

1993 - Indy Classic Touring - 200 Watt Alternator ............... . ........... . ... 3.73

1993 - Indy WideTrak - 200 Watt Alternator ...................... .... . ... ... . . . 3.74

1993 - Indy XLT, SP, SKS - 170 Watt Alternator .. . ............................. 3.75

1993 - Indy RXL, SKS - 180 Watt Alternator .... . .. . .......... . ..... ..... ... ... 3.76

1993 - Indy Storm, SKS - 180 Watt Alternator ..... . ..... . ........... .... ...... . 3.77

1994 - Indy StarLite/GT, Lite/GT - 150 Watt Alternator . . . . . . . . . . . . . . . . . . . . . . . . . .. 3.78

1994 - Indy Lite Deluxe -150 Watt Alternator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3.79

1994 - Indy Sport, SKS, Super Sport - 200 Watt Alternator. . . . . . . . . . . . . . . . . . . . . .. 3.80

1994 - Indy Trail - 200 Watt Alternator ........ . . ............. ... . ........... . . 3.81

1994 - Indy Trail Deluxe - 200 Watt Alternator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3.82

1994 - Indy 440, SKS -200 Watt Alternator ...... . ... . ............ ......... ... . 3.83

1994 - Indy 600 XCR . . ... .. ...... . ... ..... ... . ... . .... ... ......... .. ....... 3.84

1994 - Indy 440 XCR - 200 Watt Alternator .................... . . . . ........... . 3.85

1994 - Indy 440 XCR SP . .... . .............. ... . . . ... ... ... . .. ... .. . ........ 3.86

1994 - Indy 500 EFI, SKS - 250 Watt Alternator . ............ . .. ..... .. ... ... ... 3.87

1994 - Indy Classic - 200 Watt Alternator ............... .. .... .... .. .. ........ . 3.88

1994 - Indy Classic Touring - 250 Watt Alternator ............................. . . 3.89

1994 - Indy WideTrak GT - 200 Watt Alternator .. ............... .. ...... .. .... . 3.90

1994 - Indy WideTrak LX - 200 Watt Alternator ................... , . . .......... . 3.91

1994 - Indy XLT, SP, SKS, Special XTRA - 170 Watt Alternator .. ... . ............ . 3.92

1994 - Indy RXL - 180 Watt Alternator ........ .. . . . .......................... . 3.93

1994 - Indy RXL Touring - 180 Watt Alternator .......... .. .. .. ..... ... ... ..... . 3.94

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1994 - Indy Storm, SKS - 180 Watt Alternator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3.95

1995 - Indy StarLite/Lite/Lite GT ............... . ... . ..... . .................. . 3.96

1995 - Indy Lite Deluxe ..... . .......... . . . . . ....... . ... .. ..... . ............. 3.97

1995 - Indy Sport/Super Sport/Sport Touring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3.98

1995 - Indy Trail ... . . ....... . ................. . .... . ....................... 3.99

1995 -Indy Trail Deluxe .... . .. .. ........................................... 3.100

1995 - Indy 440/SKS .......... . ... .. . . ....... . .. . .... . ............. . ...... 3.101

1995 - Indy 440 XCR .... . ....... . . . .. . .... . .......... . ............... . .... 3.102

1995 -Indy 600 XCR . ....... . .. . ............ . ..................... . ....... 3.103

1995 - Indy 500 EFI/SKS/PT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.104-3.105

1995 -Indy 500 ...... . . . ................. . .. . .... . ............... ... . ..... 3.106

1995 - Indy Classic ......... . .................... . ............... .... ...... 3.107

1995 - Indy WideTrak GT ....................... . . ........... . .......... . .. 3.108

1995 -Indy WideTrak LX ... . ............................ . .................. 3.109

1995 - Indy XLT/XLT SP/SKS/PT ... .. ............ . . ....... .. ............... . 3.110

1995 - Indy XLT Touring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3.111

1995-lndyRXL . . ..... . ......... . ..................................... . .. 3.112

1995 - Indy RXL Touring ...... . ...................... . .......... . .......... 3.113

1995 -Indy Storm/SKS/PT ...... . .. . ....... . ....... . ....................... 3.114

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Headlight Adjustment Headlights may be adjusted for both horizontal and vertical aim using the following procedure.

1 . Place the snowmobile on a level surface with the headlight approximately 25' (7.6 m) from a wall.

2. Measure the distance from the floor to the center of the headlight and make a mark on the wal l.

3. Start the engine and turn the headlight switch to high beam.

4. Observe the headlight aim. The most intense part of the headlight beam should be aimed 2" (5.1 cm) below the mark placed on the wall in Step 2. NOTE: Rider weight must be included on the seat.

5. If necessary, the headlight aim can be adjusted by turning the four headlight mounting screws either in or out as needed for proper aim.

1994 and Newer Liquid Twins

Headlight Adjustment

1 . If necessary, the headlight vertical aim can be adjusted by turning the adjustment knob located inside the hood just below the headlamp opening. Turn knob in or out as needed for proper aim.

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BODY ELECTRICAL Standard Indy Models

25' (7.6 m)

Lamp Center Height

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Headlight Adjustment Knob

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Headlight Bulb Removal (Models with Metal Retaining Ring)

1. Pull rubber boot back.

2. Release the retaining ring by depressing and rotating it counter clockwise.

3. Grasp the plastic harness connector and carefully remove the harness, retaining ring and bulb assembly from the reflector assembly.

4. Grasp the bulb by its metal base and carefully disconnect the bulb from the harness.

Headlight Bulb Installation (Models with Metal Retaining Ring)

1. While holding the metal base of the bulb, connect it to the wire harness. Make sure the bulb blades are properly posffionedinthesocket.

2. While holding the plastiC harness connector, align the bulb tabs with the slots in the socket. Slide the bulb into the reflector assembly.

3. Reinstall the bulb retaining ring with the word "TOP" toward the top of the reflector.

4. Align the retaining ring mounting tabs. Push the ring in, compressing the spring, and rotate the ring clockwise to lock it in place.

5. Reinstall the rubber boot.

NOTE: Due to possible differences in bulbs, re-check headlight aim whenever a bulb or reflector is replaced.

1994 and Newer Liquid Twins

Removing the Center Bulb

1. Push down on spring until it releases from spring retainer.

2. With wire harness attached to bulb, withdraw bulb from housing.

3. Grasp bulb by metal base and carefully separate bulb from harness.

Installing the Center Bulb

NOTE: Do not touch a halogen bulb with bare fingers. Oil from skin leaves a residue, causing a hot spot which will shorten the life of the lamp.

1. Hold bulb by metal base and install into wire harness.

2. Insert bulb into housing.

3. Push spring down until it is secured by spring retainer.

4. Verify headlight aim.

Removing the Side Bulbs

1. Disconnect terminal from back of bUlb.

2. Turn bulb assembly 1/8 turn to left and withdraw from housing.,

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Wire a1 Harness ~/ ~ I >r B"'b

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Installing the Side Bulbs NOTE: Do not touch a halogen bulb with bare fingers. Oil from skin leaves a residue, causing a hot spot which will shorten the life of the lamp.

1. Hold bulb assembly by plastic base and plug into wire terminal.

2. Insert bulb assembly into housing.

3. Turn bulb assembly 1/8 turn to right to secure in housing.

4. Verify headlight operation.

Headlight Bulb Removal (Models with Wire Bulb Retainer)

1 . Push down on left side of spring until it releases from spring retainer.

2. Lift spring carefully around wire harness and flip to outside of housing.

3. With wire harness attached to bulb, withdraw bulb from housing.

4. Grasp bulb by metal base and carefully separate bulb from harness.

Headlight Bulb Installation (Models with Wire Bulb Retainer)

1. Hold bulb by metal base and install into wire harness.

2. Insert bulb into housing.

3. Carefully flip spring back into housing placing it around wire harness.

4. Push spring down until it is secured by spring retainer.

5. Verify headlight aim.

Electrical Testing The easiest and most accurate method for testing modern electrical components is with a digital multitester. Any good quality multitester will work. However, due to ease of operation and durability, Polaris recommends the Fluke Model 73 (PN 2870659). See photo at right. This instrument will provide a digital readout of the measured value of the test being performed.

Listed below are the dial symbols, their meaning and what the dial setting can be used for.

Off = Instrument Off

V - = Volts AC - measuring alternator output

V -:-:-:- = Volts DC - measuring battery voltage, volt drop, etc.

300mv -:-:-:- = Milli Volts DC - measuring small DC voltages

DIAL

RED LEAD HERE FOR AMPS

COMMON (BLACK LEAD)


Q = Ohms, resistance - measuring component resistance values - testing coils, wiring, etc.

--+- = Diode check - checking the condition of rectifier diodes, cannot be used for testing except when the diodes are out of circuit A - = Amps AC - not used for snowmobile service

A -:-:-:- = Amps DC - used to check battery charge rate, system draws, etc.

NOTE: When using the Amp settings, the red test lead must be moved to the 10A (unfused) socket on the front of the instrument.

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BODY ELECTRICAL Electrical Testing

Headlight Bulb Filament Continuity Test

1. Turn the Multitester dial to the ohms (Q) position.

2. Disconnect the wire harness from the headlight bulb.

3. Viewing the end of the bulb with the terminal blades at the 9, 12 and 3 o'clock position, connect the black multitester lead to the 9 o'clock blade.

4. Touch the red tester lead to the 12 o'clock terminal and then to the 3 o'clock terminal, noting the resistance value of each. A reading of between 2 and 5 ohms is good. An open reading indicates a bad element.

Lighting System Test (Unregulated Voltage)

1. Turn the multitester dial to the Volts AC (V",) position.

2. Disconnect the alternator to main harness connector at engine.

3. Connect one of the tester leads to the yellow alternator wire and the other lead to the brown alternator wire. NOTE: On floating alternators, the yellow/red stator wire should connect to the brown stator wire. If it does not, the system will not have a ground and will not operate.

4. Start the engine. While observing the voltage reading, increase the engine speed to about 3000 RPM. Readings of between 15 and 45 VAC are considered normal. If there is no output, refer to the Stator Testing section under Section 4, Engine Electrical.

Regulated Voltage:

1. Reconnect the alternator to main harness connector.

2. Insert one of the tester leads along the side of the yellow regulator wire connector between the insulation and the terminal. NOTE: Do not disconnect the regulator from the system.

3. Ground the other tester lead.

4. Start the engine. While observing the voltage reading, increase the engine speed to about 3000 RPM. An acceptable reading will be between 10 and 15 VAC. Voltages lower than 10 VAC may indicate an excessive system load, poor flywheel magnets, lighting coil problems, wiring problems or a bad voltage regulator. Voltage readings higher than 15 VAC indicate a voltage regulator problem or a poor ground at the regulator heat sink.

NOTE: Fuel injected models have two regulators; one for lighting and one for charging the battery. Battery charging is discussed in Section 4, Engine Electrical.

NOTE: Regulator PN 4060090 (ID mark LR 11) should not be used on machines with halogen head lamps.

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Seat Harness Troubleshooting

1. Remove the taillight lens.

2. Remove the two taillight bulbs and the brakelight bulb.

3. Separate the seat harness from the main harness by unplugging the connector at the right rear of the tank.

4. With the multitester dial set on ohms (0) connect either meter test lead to the brown seat harness wire.

5. Touch the other tester lead to first the yellow wire and then the orange wire. Observe the readings. Readings other than an open circuit indicate a shorted harness or bulb socket. NOTE: The bulb socket tangs sometimes short to ground with the bulb removed.

6. Check between the yellow and orange wires in the same manner to check for a short between the brake and running lights. If damaged wiring is found, remove the seat.

7. Tip the seat over and remove the right side seat cover staples. Locate and repair the harness problem.

8. Reinstall the staples and re-check the seat harness.

Hi/lo Beam Switch Testing

1. Set the multitester dial to the ohms (0) position.

2. If the Hi/Lo switch has not been removed from the machine, disconnect the switch to harness plug in connector.

3. With the HilLa switch in the Lo beam position, check the resistance between the yellow and the green switch wires. The reading should be less than .4 ohms.

4. Turn the HilLa switch to the Hi beam position and the multitester should indicate an open circuit (OL) reading.

5. Move one of the tester leads from the green to the red switch wire. The multitester should now read less than .4 ohms.

6. Turn the HilLa Switch back to the Lo beam position and the meter should again read an open circuit (OL).

Ignition Switch Testing (Non-Electric Starter)

1. Set the multitester dial to the ohms (0) position. Connect one of the tester leads to either of the switch terminals and the other tester lead to the other switch terminal.

2. With the switch off, the reading should be less than .4 ohms. With the switch on, the reading must be an open circuit (OL).

3. Check the resistance between each of the switch terminals and the switch body. With the switch still in the on position, there must be an open circuit (OL) reading. Readings other than those listed indicate a defective switch.

3.5

BODY ELECTRICAL Electrical Testing

L OW H' h Igi

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Yel/Rd 4~

High/Low Switch

Off On

I ::: I I Ignition Switch

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BODY ELECTRICAL Ignition Switch Testing

Ignition Switch Testing (Electric Start Models)

NOTE: Refer to the appropriate model and year wiring diagram for ignition switch wire colors and connections.

1 . Disconnect wires. Set the multitester dial to the ohms (Q) position.

2. With the key in the off position, check the resistance between the G (Ground, brown) terminal and the M (Mag, black) terminal. Th is reading must be less than .4 ohms.

3. Turn the key to the on position. The multitester should now read an open circuit (Ol).

4. Move the tester lead from the G terminal to the switch housing and re-check the reading. It should also be an open circuit (Ol).

5. Place one of the tester leads on the B (Battery, red) terminal and the other tester lead on the S (Starter, blue) terminal. With the key in the on position, there must be an open circuit (Ol) reading.

6. Turn the key to the start position. The reading should be less than .4 ohms. Readings other than the ones listed indicate a defective switch.

Ignition Switch Testing (Fuel Injected Models)

1 . Disconnect wires. Set the multitester dial to the ohms (Q) position.

2. With the key in the off position, connect one of the tester leads to the G terminal.

3. Randomly connect the other tester lead to the other terminals. The only terminal that should show other than an open circuit (Ol) is the M terminal. The M terminal should read less than .4 ohms.

4. Turn the key switch to the run position. Check the resistance between the M terminal and each of the other terminals, and the M terminal and the switch housing. All of these readings must be an open circuit (Ol).

5. Return the key to the off position.

6. Connect a tester lead to the B terminal. Randomly connect the other tester lead to each terminal. The readings must be an open circuit (Ol).

7 . Turn the key to the run position and repeat the test. All of the readings must be an open circuit (Ol), except between the Band l terminals. This reading must be less than .4 ohms.

8. With one tester lead connected to the B terminal and the other to the S terminal and with the switch in any position except start, the reading should be an open circuit (Ol). In the start position, the reading must be less than .4 ohms.

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Auxiliary Kill Switch Contacts

Ignition Primary

Engine Ground

8 Throttle Control Cutaway

BODY ELECTRICAL Speed Control Assurance Operation

Idle Switch

The speed control assurance consists of two series connected switches. If one or both switch plungers are positioned inward, the circuit is open and the engine will run.

At idle, with the throttle lever properly adjusted, the bottom switch circuit is open and the plunger is inward. The top switch circuit is closed, and the plunger is outward. The speed control circuit is open, allowing the engine to run .

As the throttle lever is actuated to an off idle pOSition, the top switch circuit is opened (plunger in) and the bottom switch circuit is closed (plunger out). The speed control circuit is still open, allowing the engine to run.

In the event the carburetor or controls malfunction and allow the throttle cable to become slack, the circuit will close (both switch plungers out), grounding the ignition system and causing the engine to stop.

Speed Control Assurance Adjustment Throttle lever free play must always provide a .010-.030" (.25-.8 mm) clearance between throttle lever (A) and throttle block (8). This clearance is controlled by the throttle cable sleeve(s) and the idle speed screw(s).

If the idle speed screw(s) is adjusted inward and the cable sleeve(s) is not adjusted to take up the throttle lever to throttle block clearance, the engine may misfire or kill upon initial throttle opening.

CAUTION: After any idle speed adjustments are made, the throttle lever to throttle block clearance must be checked and adjusted.

NOTE: When adjustments are made on models which have more than one carburetor, refer to Section 6, Carburetion, for proper carburetor synchronization adjustments.

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BODY ELECTRICAL Speed Control Assurance Testing

1. Set the multitester in the ohms (Q) position.

2. Disconnect the switch harness from the main wire harness.

3. Connect the two multitester test leads to the two switch wires.

Test 1 - Open Circuit - Run

With the auxiliary shut-off switch in the on position, the multitester should read an open circuit (OL). As the throttle lever is moved from idle to off idle, the tester should continue to read an open circuit. If the tester fluctuates and the throttle lever to throttle block clearance is adjusted properly, the switch assembly needs to be replaced.

Test 2 - Closed Circuit - Kill

The two speed control switches must make a complete circuit to kill the engine. To check the switches, pull the throttle lever out away from the throttle block. With the switch plungers outward and the auxiliary shut-off switch in the on position, the multitester must read less than .4 ohms resistance or the switch assembly needs to be replaced.

Test 3 - Auxiliary Shut-Off

The multitester should read less than .4 ohms in the off position and an open circuit in the the on position. If not, the switch assembly needs replacement.

Speed Control Assurance Testing Auxiliary shut-off and speed control assurance switches are connected and replaced as a unit from the back side of the throttle block.

1. Remove the handlebar pad and/or throttle block backing plate.

2. Slide out the auxiliary shut-off portion of the switch.

3. Remove the two screws securing the two speed control assurance switches.

4. Remove the switches noting their placement in the throttle block.

5. Replace the assembly and check its operation.

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BODY ELECTRICAL Coolant High Temperature Indicator Testing

Circuit Power In - Yel -------,1

II Temp II BlkIW-------.

Ground the BlacklWhite wire here (with the engine running) to test the light.

Engine Ground

The indicator light is controlled by a temperature/warning switch installed into the engine cooling system. When engine coolant temperature reaches approximately 2050 F, the switch closes, completing the circuit through the indicator light to ground. the system should be tested periodically for proper operation.

Lamp C~rcuit Test

1 . Remove wire from temperature sensing switch located under thermostat housing.

2. With engine idling, ground wire to engine. The temperature warning lamp on the console should light. If not, replace the lamp assembly or inspect wiring for shorts or open circuit.

Temp Light Temperature Sensor Test The temperature/warning switch is normally open.

1 . Set the multitester on the ohms (0) scale.

2. Disconnect the lamp wire.

3. Connect one test probe to the switch terminal and the other to engine ground. The meter should show an open circuit (Ol). This indicates a normally open switch. If the switch were heated to approximately 2050 F, the contact in the switch would close and the reading would be less than .4 ohms.

CAUTION: If attempting to heat the sensor to close the contacts, heat only in a water bath. Never subject the sensor to an open flame to attempt to close the contacts as sensor damage will result.

Handlebar Warmer Testing Polaris has used four different types of handlebar warmers. They are all similar in that when on Hi, they are each 15 watt warmers. Each type must be wired differently from one another due to internal resistance difference. Use the wiring diagrams on the following pages whenever troubleshooting, repairing or replacing any handlebar warmer.

The warmers are broken down into the following types:

• Type 1- Single element, stick on grid

• Type II - Dual element (Hillo) stick on grid with diode

• Type III - Dual element (Hillo) stick on grid

• Type IV - Polaris Hot Gripsn.4

3.9 8/94

BODY ELECTRICAL Handlebar Warmer Testing Type I

The Type I warmer grid is used as standard equipment on single heat units such as the Trail. Individual grid resistance is approximately 10 ohms when measured between the two element leads (1 or 2). There must also be an open circuit (Ol) between either lead and ground with the element totally disconnected.

Type I System Check

1. Remove the yellow power in wire from the toggle switch.

2. Read the resistance between the switch terminal and ground. The resistance with the switch on should be about 5 ohms. With the switch off it should be an open circuit.

NOTE: Individual grid resistance may vary slightly (1 0%) due to temperature and element manufacturing differences.

Type II

The Type II warmer grid was used as standard equipment on the 1989 dual heat units such as the Classic and 650 Indy. Individual grid resistance between the common lead (1), and either of the two grid leads, (2 and 3), is approximately 20 ohms. These grids must be wired with the 2 and 3 leads connected together and mounted on the middle switch terminal.

The diode kit (PN 2200315) must be installed as ajumper between the upper and lower switch terminal. Refer to Service Bulletin S-89-01. The common grid connection 1 must be grounded.

Type II System Check

1. Remove the yellow power in wire (switch center).

2. Measure the resistance in the Hi position (switch up). The resistance wi ll be approximately 5 ohms with all grids connected parallel. See illustration at right.

Type III

The Type III warmer grid is used as standard equipment on 1990 and newer dual heat units such as the Classic and 650. Individual grid resistance between the common lead (1), and either of the two grid leads (2 and 3), is approximately 10 ohms.

These grids are wired parallel between the left and right handlebar, and are wired in series for low heat on an individual grid. Example: low heat on each grip would have the power in to wire 2. Wire 3 would be the ground. Resistance between 2 and 3 is 20 ohms.

Type III System Check

1. Remove the yellow power in wire from the center of the toggle.

2. Measure the resistance between the switch terminal and ground. With the switch in the Hi position the resistance should be approximately 5 ohms. In the lo pOSition the resistance should be approximately 10 ohms.

8/94 3.10

GRID IDENTIFICATON NUMBER: 2536C

1

2 3

POWER IN (YELLOW) I

GRID IDENTIFICATION NUMBER: 3866B

-- BLK

GROUND

DIODEKIT ~Hj3~ PIN 2200315

B~?W 3~ 1 1

POWER IN (YELLOW)

1 2

3

GRID IDENTIFICATION NUMBER: 4010A

GROUND BAN ----r-- - ------,

L BLU -~lZJl ~ BLU :3111~

I .:3J ~~r-I ---.-,---'

BLU/AED--·1~c;.:_~~-,.

POWER IN (yELLOW) HAN OWARM[R

o

C TYPE IV

The Type IV handlebar warmer is a complete grip assembly mounted on the end of each handlebar. The dual heat version is a series connected circuit between the grips. It has an additional ballast resistor added in series to provide low heat. The resistance of each grip is approximately 2.5 ohms. The combined series resistance is 5 ohms in the high position. CAUTION: The grip kit must be properly installed and wired as shown or electrical system overloading will result.

C SYSTEM CHECK

Remove switch center connection. With a digital multitester set in the ohms (Q) position, measure resistance between switch center terminal and ground. In the off (center) position, meter should indicate an open circuit (OL). In the high position,

2.4 ohm

BODY ELECTRICAL Handlebar Warmer Testing

meter should read approximately 5 ohms. In the low ."'.'-. position, meter should read approximately 7.4 ohms. With ground terminallifted,'meter should indicate an open circuit (OL) .

HIGH-LOW HANDWARMER TOGGLE SWITCH

c Below are the correct wire to PIN numbers:

- High Circuit 1. Blue 2. Yellow - Regulated Power (A.C.) 3. Blue/Red - Low Circuit 4. Blank 5. Blank 6. Blank 7. Brown - Ground Circuit 8. Blank

C THUMBWARMER TOGGLE SWITCH

Below are the correct wire to PIN numbers:

1. Blank 2. Yellow - Regulated Power (A.C.) 3. White/Gray - To Thumbwarmer 4. Blank 5. Blank 6. Blank

c 7. Brown 8. Blank

- Ground Circuit

3. 11

HANDLEBAR HARNESS WIRE CONN.

BLUE

YELLOW

BLUE/RED

BROWN 1994

BROWN 1995

SWITCH - HANDWARMER HI-LOW

BROWN

YELLOW 8 7

WHITE/GRA

SWITCH - THUMBWARMER

8/94

BODY ELECTRICAL 1985 Wiring Diagram/Schematic - Star

Note: EC25PS-06 engine does not use pulse coil

BlK R

8/94

WIRING DIAGRAM 1985 Star EC25PS-06

OIMMER SWITCH

IQNITION SWITCH

SCHEMATIC DIAGRAM 1985 STAR EC25PS-06 (100 WATT ALTERNATOR)

STATOR PL ... TE

BRN

IGNITION SWITCH

SRN

THROTTLE SAfETY SWITCH

Bi'

r/ l£O

.. ,

3.12

c=-~~ j ~ Tlllllt'11uWlrgcr

LONG TRACK

STAR & SS

)

)

c WIRING DIAGRAM

SS EC44-2PM-3100 Long Track EC44-2PM - 5000

BODY ELECTRICAL 1985 Wiring Diagram/Schematic - SS, Long Track

1IF~~~:r;C3~::3~~E ~~~2cc::::Y BRM[ LICHT SWITCH

.r. -'J, --"9.---=:=J I I I I I I 'I: ~

IQNrTlON SWITCH

SCHEMATIC DIAGRAM

SS EC44- 2PM-3100 (120 WATT ALTERNATOR) LONG TRACK EC44- 2PM-5000 (1 20 WATT ALTERNATOR)

Note: EC25PS-OG engine does not use pulse coil

STATOR PLATE

BRN

IGNITION SWITCH

BRN

THROTTLE SAfETY SWITCH

3_13

'"

'" V/ R[D STAR & SS

'" 8/94

BODY ELECTRICAL 1985 Wiring Diagram/Schematic ~ Indy Trail

WIRING DIAGRAM 1985 INDY TRAIL EC44-2PM-2100

SCHEMATIC DIAGRA M 1985 INDY TRAI L

EC44- 2PM- 2100 (120 WATT ALTERNATOR)

BLK

8/94

l '''''''''''''00

IGHITIOH SWITCH

'"

3.14

)

R£D

TICH{)METER (uCIII)

TAILLIGHT

SPEEOOMETER LIGHT

OR'

c

c

c

WIRING DIAGRAM 1985 INDY 400 EC40PL-02

BODY ELECTRICAL 1985 Wiring Diagram/Schematic - Indy 400

SCHEMATIC DIAGRAM 1985 INDY 400 EC4OPL-02 (120 WATT ALTERNATOR)

REGULATOR

TACHOMETfR (LIGHT)

BRAKELIGHT SWITCH

OR' TAILLIGHT

SPEEOOM[1[R LIGHT

.RM

3.15 8/94

BODY ELECTRICAL 1985 Wiring Diagram/Schematic - Indy 600, Indy 600 SE

WIRING DIAGRAM 1985 INDY 600, INDY 600 SE

EC60PL-02

SCHEMATIC DIAGRAM 1985 INDY 600, INDY 600 SE

EC60PL-02 (120 WATT ALTERNATOR)

Handlebar Heaters standard on Special Edition Optional on Indy 600

8/94

I I I I I I I

--, I I

I I I I L.. ______ -'

i.!li .ii.

~ loo.oTS'"'t'CM

leNITION SWITCH

SPARk PLUGS

3.16

Handlebar Heaters standard

on Special Edition Optional on Indy 600

TAIlliGHT

o

o

J

c

c

c

c

c

WIRING DIAGRAM 1986 Star EC25PS-06

IGNITION SWITCH

BODY ELECTRICAL 1986 Wiring Diagram/Schematic - Star

5- lOIE~

.. -=0=' -

SCHEMATIC DIAGRAM 1986 STAR EC25PS- 06 (100 WATT ALTERNATOR)

Not. : EC25PS.()6 engine does not use PUIM coli

STATOR PLATE

BRN

IGNITION SWITCH

BRN

THROTTLE suny SWITCH

3.17

('-.f ,- .J~L.!Q.Hl. l'"

,,, I L~ SWITCH I

I I BRAnLIGHT I' I LONG TRACK r - '- ___ _ J I

~~~~----~~~----~ I

.'" I

''" Yl RED

."

I I TAILLIGHT I L ___ ___ -1 ...

STAR & SPRINT

8/94

BODY ELECTRICAL 1986 Wiring Diagram/Schematic - Sprint, SS, Long Track

WIRING DIAGRAM

Sprint EC34-2PM-01 Long Track EC44- 2PM - 5100

Note: EC25PS·06 engine does not use pulse coil

BLK R

8/94

STATOR PlATE

ITl=----

IG NITION SWITC H

SCHEMATIC DIAGRAM

SPRINT EC34- 2PM-01 (120 WATT ALTERNATOR) LONG TRACK EC44-2PM-5000 (120 WATT ALTERNATOR)

IGNITION SWITCH

SRN

THROTTlE SAfETY SWITCH

SPEEDOMETER LIGHT

('-" ___ --I~l~HLI",

",I L~ SWITCH ,-

I I ___ ~R~E!:'.."I!:..J' I lONG TRACK

r - I ~~~ ______ ~-L ____ ~ I

'" I I

I TAILLIGHT I 'AN

L ___ ___ .J

'" STAR & SPRI NT

" RED

'AN

3.18

c WIRING DIAGRAM 1986 INDY TRAIL

EC50PM-01

BODY ELECTRICAL 1986 Wiring Diagram/Schematic - Indy Trail

i _____ __________ '.

'"

SCHEMATIC DIAGRAM 1986 INDY TRAIL

EC50PM- 01 (120 WATT ALTERNATOR )

3. 19

SP££OOM£TER LIGHT

'"

.ED

TACHOM£TER !liGHT)

BRAKELIGHT SWITCH

'"

BRAK£Ll GHT

'" TAILLIGHT

8/94

BODY ELECTRICAL 1986 Wiring Diagram/Schematic - Indy 400

WIRING DIAGRAM 1986 INDY 400 EC40Pl-02

'"

8/94

SCHEMATIC DIA GRA M 1986 INDY 400 EC40Pl- 02 (120 WATT ALTERNATOR)

REGULATOR

IGNITION SWITCH

'"

SPHOOMETER lICHi

"

3.20

)

(

TACHOMETER (LIGHT)

TAILLIGHT

c

c

BODY ELECTRICAL 1986 Wiring Diagram/Schematic - Indy 600, Indy 600 SE

WIR ING DIAGRAM 1986 INDY 600, INDY 600 LE

EC60PL-02

II

-- --,

I I I I

I I

I I I I i I L ______ -'

SCHEMATIC DIAGRAM INDY 600, INDY 600 LE

EC60PL- 02 (120 WATT ALTERNATOR )

Handlebar Heaters standard on Limited EdItion

Optional o n Indy 600

SPAR> PLUGS

3.21

Handlebar Heate rs standard

on l imited Edit ion

Optional on Indy 600

TAIlliGHT

" .... lIo.n ~.,

8/94

BODY ELECTRICAL 1987 Wiring Diagram/Schematic - Star, Star Trak

1987 WIRING DIAGRAM STAR, STAR TRAK EC25PS- 06

f

r -

) I I

,

~--TOENGIN£ _ 81lN

rFr==;;~C~~ TO ENGINE

~ = _ ~"~~O~N==~ I

"s~::,'~",H: ~w ~" ' =-0-, & ,~:::~; ';" • " '" r-~ ~J SAfETY ~ - -='r ~~ I

SWIICIt(S : : : :

I 1. I I ~ Y I

Note: EC25PS·06 EC342PM ·Ol - 02

Do not use separate ignition pulse coil

8/94

O IMM ER SWITCH

IG NITIO N SWIT CH

1987 SCHEMATIC DIAGRAM STAR, STAR TRAK EC25PS-06 (100WATT ALTERNATOR)

R EG UL ATO R

THROTTLE SAFETY SWITC H

NEUTAAL SWITCH

I : '----""''-----'

l __ ._N~!!!..R!'1 !,..1 9..H.! _J

3.22

j

sPEEDOMETE R

o

c

c

BODY ELECTRICAL 1987 Wiring Diagram/Schematic - Sprint, Long Track (RLR)

1987 WIRING DIAGRAM STAR , STAR TRAK EC25PS-06

SPR INT EC34-2PM-01 LONG TRACK (RLR) EC44-2PM - 5100

CJ::'CC' ==I=-

r= 1-- :.- ,"" , ' : '

~-BRN TO ENGINE

_ BRN . !lR N--.c::a:CJ;>...--1

, , I

rF~=...F r::::::::F TO ENG IN E

~=~::~O~N==~ ~:R~PRI~J I

TAILLIGHT & BRAKElIG . lT

STAR TRAK, LONG TRACK (RLRI

~==~~~~~~~-~ BAAI(ELIGHT SW IT C H

-- - - - 6flN ___ _ BRN I V AN r- 1;lnN 0 II

&;~~~~f~:YE tj" I G~I~~J- '" 'fREGUUHOR

sPEEDOMETE R

s~~:~~~s .:or ~ .. , : I "

Note: EC25PS·06 EC342PM '()1-02

Do not use separate ignition pulse co;l

~~ I :

DIMM ER SWIT CH

IG NITION S WIT C li

1987 SCHEMATIC DIAGRAM SPRINT EC34- 2PM-01 (120 WATT ALTERNATOR)

LONG TRACK (RLR) EC44-2PM-5100 (120 WATT ALTERNATOR) Refer to page 20k for Sprint Electric Start Schematic Diagram

IGNITION SWITCH

RE GULATOR

THROTTL E SAFET Y SWITCH

3.23

SPEEDOMETER LIGHT

TACHOMETER

l~ re",OC",K-Q,--L./

I I LONG TRA CK ~~E~G~J I (ALR)

I I I I

I TAILLIGHT I L ______ .J ,RN STAR & SPRINT

8/94

BODY ELECTRICAL 1987 Wiring Diagram/Schematic - Indy Sport, Indy Trail (133 SKS)

1987 WIRING DIAGRAM INDY SPORT EC34- 2PM- 03

INDY TRAil (133 SKS) EC50- PM- 01 ~=~'"""'''

8/94

L K BAN

l.!!;:::::::::::=;:;:;;:-;C.'" ~ • ~n's"u' o" U SWITCH & THROTTLE U ",""W,,,,,

1987 SCHEMATIC DIAGRAM INDY SPORT EC34- 2PM- 03 (1 20 WATT ALT ERNATOR)

INDY TRAil (133 SKS) EC50-PM-01 (120 WATT ALTERNATOR) Indy Trail Electric Start Schematic reference page 20k

3 _24

HANDLEBAR HEATERS

STO ON TRA IL. OPT ON SPOR T

SPEEDOMeTER LIG HT

, nN

TAILUGHT GE 16 1

BODY ELECTRICAL 1987 Wiring Diagram/Schematic - Indy 400 (1 33 SKS), Indy 600

I V- TO ENGINE

'"T '"N1 9RN-=a;. ~

1987 WIRING DIAGRAM

TEMPERATURE LIGHT

r I I I I I I I I I

INDY 400 EC40PL - 02 INDY 600 EC60PL- 02

"'TEMPERATUR E '" ~ 8 rSW_'_TC_"c;aIIll __ r

SPEEDOMETER J G

" : !

v

'" TAC HOMETER

HEADLIGHT

" , , ,< , :~ ,

' :

,f~ fl ___ , _____ _

-:,'

, ,

.:~::~ ~~.

REGULATOR

HANDL EB AR ,; EATEAS OPTIONAL

.• : - AUXILIAR Y SHUT -OFF SWITCH il::::~' ,-- ~~Ww< & THR OTTLE SAFETY SWITCH

LIGHT SWITCH

1987 SCHEMATIC DIAGRAM INDY 400 (1 33 SKS) EC40PL- 02 (1 20 WATT A LTERNATOR)

INDY 600 EC60PL- 02 (1 20 WATT ALTERNATOR) Handlebar heaters optional on both models

y 1- - - - - --- -------------- ----, , :

,I I

I I

I I I I I I I 1.-- _____ _ -1

L _______ .J INDv 600

INOV 4001133 51(51

TAILLIGHT GE 161

8/94

BODY ELECTRICAL 1988 Wiring Diagram/Schematic - Star, Star Trak

1988 WIRING DIAGRAM STAR, STARTRAK EC25PS-06

~-BAN TO ENG IN E

_BRN

Z BA N ----=t3: Q=>----.o

rr==;;;9.l'\-.Y' ~ TO ENG IN E

, I

~ ~ ~~~=O~N==~ ~"",Nn~ l ~y~

SlAA TRAK. LONGTRAK ALR TAILLI GHT &- 8AAKELl GI-1T

, I I I I I

-- ---- ~D=="'~ ":. O R N R N r-"~~ I

I y Y-~' -- - - - , N __ - - " N I , >-<>'U < ""DO"""

~ ~Ciij'""""-1988 SCHEMATIC DIAGRAM D'"" '~"CH ,---+---1

STAR, STARTRAK EC25PS- 06 (100 WATT ALTERNATOR) tGNITlO N SWITCH

8/94

LOW flANGE r L IG Hl lY[lLOW I

I Lt,~~ ti :~~~~~ ) IllV,'ANG( L 'G"r II1l0l

J

SPARK PLUGS

THROTTtES AFET V SWIT C H

, ;====== 1'---' r I r I

r I ~ ~ _____ __ ~~N~~~ ~W~T.:: ___ J

3.26

c

c

c

BODY ELECTRICAL 1988 Wiring Diagram/Schematic - Sprint, Long Trak RLR

lOWfl A,NGE ,. U GIH IYELLOWI

I L~~~~ ~GARNE~~I R EV RA,N GE I

LIGHT IREO t J :

_c ___ =-r __ ~ ___ j: __ = __ = ___ = __ = ___ ~ __ = ___ = __ = __ = ___ = __ = ___ = __ = ___ = __ = __ = ___ = __ = ___ =-=-=_ -=---=.!--:

1988 SCHEMATIC DIAGRAM

n mOTT LE SAFElV SWITC H

1-----------------------------':==========J1:,rONt"HAK-"LI! I LO W RAN GE SW LONG H I AO( IH V U l $ ( : , , : ~ IG NI I IO N SWII CH , , , , , , , ,

lOW II ANG~

r l lG Hl lv t llOW I

I H IC H flA Nt..f Lll,HI IGHnNI

, ... +--f-...J ~ Il lV II AN ('E I LIGHI IAEOI ]

i _~t_~_~_~_t_=_~_=_~_=_=_~_=_=_=_=_=_==_=_~_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-____ ~_=_=_=_=_=_=_=_=_~_~_~_~_~_~_~_~_=_=_=_=_=_=_~_ ,

3.27

I j TAILUGt-H L 'ii'R"N -----....i

8/94

BODY ELECTRICAL 1988 Wiring Diagram/Schematic - Indy Sport, Indy Trail (All Except ES)

1988 WIRING DIAGRAM INDY SPORT EC34- 2PM- 03

INDY TRAI L (All Except ES) EC50- PM-01

8/94

: :1

~ ~

LIG!-" 5W II C"

1988 SCHEMATIC DIAGRAM INDY SPORT EC34-2PM-03 (120 WATT ALTERNATOR)

"AN D I. EB AA " E ATERS STO ON TRAIL . O PT ON SPORT

INDY TRAIL (All Except ES) EC50PM-01 (120 WATT ALTERNATOR ) Indy Trail Electric Start Schematic reference page 20k

BLK

,RN

HANDLEBAR HEATERS

STD O N TRAIL. OPT O N SPOR T

IG NITION SWITCH

3.28

SPEEDOMETER LIG HT

,RN

T AI LLIGHT

TAILLIG HT GE 161

)

c

c

BODY ELECTRICAL 1988 Wiring Diagram/Schematic - Indy 400 Classic

1988 WIRING DIAGRAM INDY 400 CLASSIC EC40PL-03

"

~~~~'r=~ \ :;-J~: i!~: J ~~i .. ~;(~:t ~ ! ~"... I Ii ~ "UHRS

~::;;"J ' -lw ~O,:,\~:" I ~;;; j i ~ "w, 'ir'

~:::.;:}. '"'_~" "e ." i L 0 '?::'i:;~~"

-"~:,~;"': ~

(Y." C);':;.' ::.:' .. SPllOO"'(I(R '''C''OMll( R

1988 SCHEMATIC DIAGRAM INDY 400 CLASSIC EC40PL - 03 (1 20 WATT ALTERNATOR)

'-~:B--'=--o.o-~B=AN ~~~~~:~~i~ 0' , c' -=- L __ _ -'

'-----+---- --.----, FlEAR VIEW OF IGNITI O N SWITCH

BR AI(ELIGHT SWITCH

3.29 8/94

~ <.0 ~

w w o

'" r

" 3i

'" Jl Z

~

::< I I ~

'" r

'"

z

1988 SCHEMATIC DIAGRAM INDY 400 (SKS) EC40PL-02 (120 WATT ALTERNATOR) INDY 650 (SKS) EC65PL-01 (120 WATT ALTERNATOR)

r------ ---- -, 1------------ Y I ---

D REGULATOR

I TEMPERATURE I I SENSOR I I I I I I

~ARK_;;;:_UGS I

'" r C m

~ II::< o

~ I ~

'" r

'" ~

z

Y

THROTTLE SAFETY SWITCH

BRN

BLK

____ .J

----,

BRN

W

W

BRN

I I I

TEMPERATURE LIGHT ~ ...... _----------

'+ HANDLEBAR v_I.!-::-:: ~Y/ I HEATERS

-<

IGNITION SWITCH

'" r

'"

'" r

"

y

Y

RED

BLK

TACHOMETER (LIGH T)

8AAKELlGHT SWITCH

TAILL IGHT

Y

8AAKELJGHT

I I p~1

II I

SPEE~OMETER LIGHT

I I I I I I I I

[i>~1 i I I I I I

Ll r~J I ___ -.J INDY 400 1133 SKS)

I I I I I I I I ~I I I '-______ .J

IND Y 600

LIGHT SW ITCH

BLK SPARK PLUGS

ORN

~ GRN

BRN

"""'OJ COo ~c :e-< -·m ~.r :::sm COo c-t _. :0 Q)

COO ""'» 3 r -en (")

:r ('I)

3 Q) e. (")

:::s a. '< +:0-o o -en

" en -:::s a. '< C» <.n o -en

" en -

CAl CAl

CD "-<.0 ~

COLOR CODE

BLK BLACK BR N BROWN RED RED BLU BL UE YEL Y EL LOW

0 ORANGE GRN GREEN W WH ITE

() n ,,,--,,I n

-:-

E YEL -------------,

I

IGNIT ION SWITCH

! III CO"' BRN--

BLK

OFF ON lOW HIGH

::: .... 1 !1-----1 IGNI TION SWI TCH

GRN~ YEL

VE L/ RED

HIGH / LOW SW ITCH

w

RED

cCJ: ~ BR A KELIG H T

SW ITCH

AUXILIARY SH U T-OFF SWITCH & THROTTLE

SAFETY SWITCH

BRN

2 a: C)

o w

~ w >

TAILLIGHT GE 161

8RAKElIGHT GE 94

8RN~ TAILLIGHT YEl~ GEl61

HI GH / LOW SW ITCH

HEADLIGHT

n

..&.

<0 (X) <0

~ :::!. :J

CO

o Q)

CO ""lO:J Q)O 3 0 '-< !am Q)r~""l m (1)0 --t ~JJ -to @l> ",r-

~ CD ~

w w I\.)

BAN

BLK

IGNITION SWITCH

OFF RUN II . -- Uj

lOW H IG H

8 ~

;; ~

'"

;:

;: Z ~

VEL

BRN

2

~

BRN

F-OR OPTIONAL HANDWARMERS

COLOR CODE

BLACK

BROWN REO BLUE Y E L L OW

ORANGE GREEN

BLK

BAN

REO

BLU

VEL o GRN

w WHITE

m~ BAN~

SPE c. DOME TE R

VEL~r---- I VEL I I Of"T IONAL BArJ~ I EOUIPMI:::NT

BRN 1

I J I I ~ VEL-----"-( I _ ____ _ ...J

TACHOMETER

I 1

1

I I

IGNITION SWITCH

w

REO

~~ BRAKElIGt-:T

SWITCH

AUXILIARY SHUT·OFF SWITCH & THROTTLE

SAFETY SWITCH

-~BAN~ Y E L ----LI\P"'

TAILLIGHT GE 161

BRAKE LIGHT GE 94

TA ILLIGHT GE 16·,

BRN ) J J IL. __ ----j

BLK I-_ ~ 0 __ 0 ___________ 1

I :- VE~----T 1 " LU ~ I GRN~ YE.

VEl/REO

H!GH LOW BEAM SW ITCH

HIGH/ LOW SW I TCH

I I I I I RELAV I I I

o 0 w w

-= I HEADLIGHT

,-1-------- --I VEL

! 11r"" J i ~ "'?"",",," i ---~ I 1

1 I

I I I _ ___ _

lLM BR~

I SHIFT REO f YEl

I POSITION SWITCHES

I I I

BRN

--'--

HiliH RANGE (GRE EN I

nEvERSE lREDI

lOW RANGE (ORANG E)

(L TA ONLY)

-----------

II ! = IGNITION :::~ OH "" " .. , 7 -w --I SWITCH Reo I

I I BLU G / S

I I IES ONLY) I 8 TO IGNI TION SWITCH (8 TERMINAL! __ _ _ _

I 0 TO IGNITION SWITCH (S TEnMINAL!

IGNITION SWI TCH Wine COLORS G TERMINAL - BROWN

8 TERMINAL - RED 0 M TERMINAL - BLACK S TERMINAL - BlUE 0

I I I

""""OJ <00 fgo ::e-< -·m ~. 1 ::lm

<C(") 0-4 _. JJ Q)

<C(") .,» 3 1

en "C ~. ::l -m sn 1 o ::l

<C -t Ql

" -~ JJ -

CAl CAl CAl

COLOR CODE

BlK BLACK

I BRN BROWN

RED RED Bl U BLUE VEL YELLOW :;; 0 ORANGE " GRN GREEN ~ W WH ITE

(Xl --c.o ~

I

I i< z g;

I i< Z " "

()

r--- BRN

BRN ------_~

FDA OPTIONAL HANDWARMEAS

w

RED

--------- BlK

OFF ON LOW HIGH

:~; If-f-I -----l IG NITION SW ITCH

GRN~ VEl

VEl/REO

HIGH / lOW SWITCH

n n

YEl-£\ BRN ~ SPEEDOMETER

,--- -,

II ~ OPT ION AL Y:~:~U;· :rACHDMETER

~ BAN I I EOUI PMEN T

VEl --- ---- -----=Hr---i L __ -..J

w~ BRAKE LIG HT

SWITCH

BRN~ YEL~

TAILLIGHT GE 16 1

BRAKE LIGHT GE 94

TA ILLIG HT GE 161

H I,lO BEAM SWITCH

BAN --c::J FOR OPTIONAL HIGH BEAM

.-------c::J IN 0 Ie A T OR o

o w 2 w ~

z >-

g; HEADLIGHT 4" 2 ~

..... CO (X) CO

;; :::!. ::::J

(Q

C Q)

(Q ., Q)Cl 3 0 '0 CJ)-< "Om or-~m CJ)O "0-4 0:0 =+(5 G)> -4,

Q2 <0 ~

W W .j::::..

COLOR CODE

BLK . BLACK BRN BROWN RED RED BLU BlUE YEL YEllOW 0

w 0 ORANGE 0: GRN GREEN ~ W WHITE

;:

I I

z 0: on

;: Z 0:

'"

c.o. IGNI T ION ASSEMBl Y

OFF ON

::: H-I I -----l IGNI TION SWITCH

BLK

FOR OPTIONAL HANDWARME RS

-=-

IGNI TION SWITCH

BA N ~

BRN --------------~

LOW HIGH

GRN § YEL

VEl/REO

HIGH/ LOW SWITCH

w

RED

TEMPERATURE lIGI-;T IRED LENS }

YEL~ aRN ~ SPEEDOMETER

YEL£) Y EL BR;$ TACHOMETER

BRN

YEL ')

w~ BRAI<ElIGHT

SWITCH

TA ILLIGHT GE 161

"--7--L-IV BRA~:~~GHT

BAN ~ TAILLIGHT v EL ~ GEl6 t

HI , LO BEAM SW ITCH

BRN -c:::J FOR OP TIONA L H IGH BEAM

,------e::] INDICATOR o

o w 2 w ~

40:2~

z > g;

HEADLIGHT

u

~CJ COo me :e -< -·m :::!. r-:lm c.co e-i _. JJ Q)c.co ~»

~r-

:l a. '< ~ o

5=> 01 o ~o

01 o o en "tJ

(;.)

(;.) (Jl

~ <0 +:>

COLOR CODE

BLK BLACK

BRN BROWN

RED RED

BLU BLUE

YEL YELLOW

0 ORANGE

GRN GRE EN W WHITE

BRN

BLK

RED

BLU

r)

YEL

I I '"" z ~ iii

ii:: j " ~ ~ Z '" " '"

I BU<

OF F RUN START

~ IGNITION SWITCH

G // G I / S M

IGNITION SWI TCH

n

-" w >

r=n IGNITION

HANDWARMEA

ACCESSORY LIGHT

YEL

LOW DlllEVEL SENDER

-::-

w ~ BRAKELIGHT

SWI TCH

.. ~" ~ ~~I I~LlARY SHUT-O FF

BRN

WIRE COLOR

G TERMINAL - BROWN - GROUND

8 TERMINAL - RED - BATTERY

M TERMINAL - BLACK - IGNITION

S TERMINAL - BLUE - STARTER

W ~V SWITCH & THROTTLE d SAFETY SWITCH

STARTER RELAY

Oil LIGHT IRED LENSI

TEMPERATURE LIGHT !ReO LENS )

YEL~ BRN~

SPEEDOMETER

ya£) VEL ~ TACHOMETER BRN~

~8RN

TAILLIGHT GE 161

BRAKE LIGH T GE 94

.BRN ~ TAILLIGHT YEl~ GEI6!

Hl / lD BEAM SW ITCH

Br:-=D ~ § w >

HIG H BEAM INDICATOR l BLUE LENS}

HEADU0HT

()

..... CO ():) CO

~ ~" ::l ce C iii" ttl ceO QJc 3-< 1m (I1rom 0(") (")-4 -JJ cutJ)(")

~" » or-

co ---co .j:>.

W W (J)

COLOR CODE

BLK

BRN

RED

BLU

YEL

a GRN

W

BLAC K

BROWN

RED

BL UE Y ELLOW ORANGE

GREEN WH IT E

IGNITION SWITCH (STAND ARD )

TRAIL

Y E L~ BRN~ SPEEDOMETE R

VEL . BRN~ TACHOMETER

YELV ~BRN

( YEL )

IGNITION SWITCH

TAILLIGHT GE 161

BRAKELJGHT GE 94

BAN • w b~ .... Ht ".

0 w cr :;; -'

'"

~

~

" :i5

BRN

BLK

Z a: '"

• BRN

BLK

OFF R UN

II LOW HIGH

GRN~ VE L

YEL/R EO

H IG H/ LOW SW ITCH

REO~ Iw AUXILIARY SHUT OFF g SWI TCH & THROTTLE

~ SAF ET Y SWI TCH

(i) 0 _____ _ 0---t;;r-1 ",o~ YEL

,

IGNITION SW I TCH

8RN

BLK

REO

8LU

OFF RUN ST AAT

~ 0) TO Al TERNATOA OUTPUT - YELLOW WIRE

RELAY

~ -:-

BRN~ YEL~

H IGH LOW SW ITCH

BAN -c:J ,----= Cl

Cl w W :r

TAI LLIGH T GE 161

FOR OPTIONAL HIGH BEAM INDICATOR

~ ::;

~~~ ~ cr "

- BRN .

IGNITION SWITCH

// @M

G I / S

IGN ITION SW ITCH WIRE COLORS

G TERMINAL - BROWN

B TERMINAL - RED

M TERMINAL - BLACK

S TER M INAL - BL U E

o TO IGN ITION SWITCH (8 TERMINAL) ES ANO DELUXE ONLY

o TO IGNITION SW ITCH (S TERMINAL! ~ FOAE S AN O DE LUXE ONLY

...A.CJ COo ~c ::-< -·m ::::! •• :::lm (Q(")

C-f -. :IJ Q)-(Q(")

"""» 3' ::::s Co '< -f """ 2:!. m en en _"0

en

" en c CD c: ><

,St> en c: "0 CD

~ """ Q) ;II;'"

..J -«(/) ()~ -(/) [[-... 0 ()Lt) W CO ..J~ w'C >c c OE £Q«l ...

C)

"~ c C) C "t: ;: 0) CO 0) ,-

f \

V

BLK BAN A EO BL U YEL 0 GAN W

BAN

BLK

;'0 • VEL

BLACK Z BROWN l5 AED :. BLUE " YE L LOW ORANGE

GAEEN WHITE

BLK

OFF ON LOW HIGH

GAN~ YEL

VEl/RED

II IGNITION SWITCH

H IGH / LOW SWITCH

u

BLK

~ w >

HANDWARMER

-=

TEMPERATURE LIGHT IRED LENSI

"'-=8 SPEEDOMETER

YEL£) YEl~ TACHOMETER BRN~

~BAN

C YEL )

BAN •

BRN

IGNITION SWITCH

RED

~ o BRAKE LIGHT

SWITCH '----' AUX IL IARY SHUT-OFF SWITCH & THROTTLE

SAFETY SWI TCH

L------------- BRN ____________________________ ~

u

o w

§ w >

BRN~ YE L~

HIGH / LOw SWITCH

TAILLIGHT GE 161

BAAKELIGHT GE 94

rAILlfGHT GE 16 1

HEADLIGHT

~

~ ex)

I"('f)

('f)

..J «

~

~ "co -en ..: CO -en

E CO "-(0)

- CO a: .-t-C 0 0) W r:::: ..J '':; w·->== cO 00) m~

COLOR CODE

BLK BLACK BRN BROWN

RED RED

8LU BLUE YEL YE LLOW

0 ORANGE

GRN GREEN W WH ITE

2

;; a: co

0 w ;; a: 2 ~ ..J a: co co

~ t9 O F F ON

:~: II IGNI TI ON SW ITCH

BLK

'--

r YE L----------------------~

IGNI TION SWITC H

BRN ~~ __ __

BRN -------- --,

LOW HIGH

'""a YEL

VEL/RED

HIGH / LOW SWITCH

W

RED

~O

AUXILIARY SH U T-OF F SWITCH & THROTTLE

SA F ETY SWITCH

BRN

2 a:

"

0 w a: :J w >-

~

TA I L LI GHT GE 161

BRAKELIGHT GE 94

TA IL LIGH T GE 16 1

H IG H / LOW SWITCH

II I I I HEAD LI GH T

OJ C")

C")

'<:T O'l --CO

eN eN CD

co ---<.0 .j:>.

,..)

COLOA COD e

BLK BLACK BR N BROWN RE D RED BL U BLU E YEL Y ELLOW

0 ORANGE GR N GReEN w WH I T E

LOW H IG H

GRN § VEL

YEL/ RE D '

H IGH/ LOW SW ITCH

Y EL

F OR O PTION AL HANDWA RM ERS

~ Y EL ~ I GN ITION SWI T CH

R ED I AU XILIARY SHU T·OFF W SWI TCH & THROT T L E

~o BAAKEUGH T

SWITCH

r ~ [ [ '"

r---B LK BRN ~ =11 11 I

o 'M''',"''' ,

I bj C.D . IGNI T ION

ASSE M Bl Y

O FF RUN START

I

1° -=-

z :;;

+ .,. 12V BA TTE RY

BRN~ BL K

R ED

BLU / ~ o G I /.

WIR E COLOR

G TE RMINAL - BROWN - GROUND B TERM INAL - RE D - BAT TE RY M TER MIN A L - BLACK - IGNI T ION 5 TE R M INAL - BLU E - STARTER

IG N IT ION SWI T CH

z ~

'"

n

YEL~ - BR N D SPEE DOM ET ER

---, r I ~ I TACHOM ETE R

OPTIONA L EQUIPM EN T

BRAK E L IGHT GE 94

TAILLIGHT GE 16 1

HI / L a BEAM SWITCH

BAN --c=J FOA OPTIONAL HIGH BEAM

~ IND ICAT OR

" ~ w >

HEADLIGHT

..... CO CO o

~ ~, :J

(C

em 0)' 0 (CO @< 3 m " C/)m

"0 0 ..,-f -, ::xJ :J-0 m» c/).

I-C!)

t: 0 a.

CI)

t 0 a.

CI)

~ '0 e::

....IE <t~ ()O) -ra a: .-I-C (0) We:: ....I 'i: w·->3: co 00) al~

COLOR CODE

BLK BLACK BRN BROWN REO REO

BL U BLUE YEL YELLOW

0 ORANGE GRN GR EE N W WHITE

0 w X

" ..J CD

I 2 ;; a: CD

I ;;

" a: ao

;------------------BLK

I , ,0 -~/

CO IGNITION ASSEMBL Y

OFF ON·

:~~ I I _u3 IGNITION SWITCH

BRN

BRN

o

FOR OPTIONAL HANDWAAMERS

FOR OPTIONAL ACCESSORY

LIGH T

()

";~ SPEEDOMETER

( "'() L I -BRN : ~ BR~ TACHOMETER

YE L ')

IGNI TI ON SWITCH

LOW HIGH

GRN§ YEL

YEL/REO

HIGH /LOW SWITCH

W

REO

w~ 8RAKElIGHT

SWITCH

2 a: "

BRAKE LIGHT GE 94

B R N -T"!>-. YEL~

H I , LO BEAM SW ITCH

BRN ---c:::J FOR OPTIONAL HIGH BEAM

r---e:::::J INDICA TOR o w a: ::J w >-

HEADLIGHT

o """ C")

'<:t

~

...J~

«~ 01-- Q) c:::"'O I-- ,-0;: W>a ...J"'O we: > -: c E Oro Dl~

C) ro C C) e: 'i:

3: o 0) 0) '9"'"

~

COLOA CODE

BLK BLACK BRN BR OWN RED RED BLU BLUE YEL V ELL OW

0 ORANGE GRN GAEEN W WHITE

u

i;. Z g;

YEL

r------------BLK---------------1-----

HANOWARMEAS

,I I I

B~ T EMPER AT - 1 (1iJl ,RED ~~Sr 'GHT I YEL I

WIOETRAK J ONL y ------

FOR OPTIONAL ACCESSOR Y

LIGHT I - ·~irt I ~ Sf I 0 ==€)

(SU PEATAAK ONL Y)

YEL

L.3 __ .J -BRN : SPEE DOMETER

YE L -SAN ' .

BlK/ REO --------____ ---'

d YEL ) I §()

YEL

~ BRN ~ TACHOMETER

IGNITION SWITCH

TA ILL IGHT GE 161

rr ~O

--------'--~\ ~.I1 I B BRAK;LlGHT _-----BAN ? ~ W-------='=.=:1~ SWITCH

-nrAUXILlAAY SHUT OFF

BRN~ BRAKE UGH T G E 94

REO W SWITCH & THAOTTLE o '''''''"'''' LBAN~ TA ILLI GHT YEL~ GEl61

r----------- BLK

C.D. IGNI T ION ASSEMBL Y

OFF

BRN [f

10 I

ON

BlK ~ '-'-----------

IGNITION SWITCH

-=

LOW H IGH

GRN § YEL

YEL/RED

HIGH LOW SWITCH

YEL

SHIFT POSITION SWITCHES

REO/ VE L LI ----'1').----1

BRN

-L

-:-

HIGH RANG E (GREEN)

REVERSE (R EOI

l OW AANGE (O RANGE)

BRN-eJ

I FD A OP TI ONAL

HIGH BEAM INDIC ATOR

HEAD LIGHT

.q Ol CO

..-

..q ("')

(1)

>< ::J Q) C

~ I-~ '0 e:

....IE <t~ (.)0') - co a: .-I-C (.)0') We: ....I 'i: w·->== co 00) m~

BlK BRN RED

Bl U VEL

a GRN W

BLACK BROWN

RED

BL U E: YEL LOW ORANGE GREE N WH ITE

IGN I TION SW ITCH 1ST ANGARO I

TRA i l

0 ~

:r

" ~

'"

~ Z

~

~ Z :r " • I

co IGNITION A$SEMBl Y

OFF RUN

:~; HI !f-----1

GRN §"OW HIGH

YEL

YEl/R ED

HIGH / LOW SWITCH

()

BlK

FOR OPTIONA L ACCESSORY

LIGHT

YEL~ SPEEOOMETER BRN-V

VEL BAN ; .

!.--W ') E~ ____ ~~~ ________ ~~ _______________ YEl L E

YElU ~. TACHOMETER

BRN

BRN

BRN

IGN I T ION SW ITCH ~ W" . I~ ,.""".".",.

RED ~ \w A UXILIARY SHUT -OFF M SWITCH & THROTTLE ~ SAFETY SW ITCH

f.:\ (2) _________ 1 o ----1- 1 o _ -- I

- ' I 'W ---1 I

RE L AY 1

I I

I

H IGH i lOW SWITCH

BAN -a ~ o o w

W a;

~2 ~ z >

:r <:J

- BAN .

TAILLIGHT GE 16 1

8RAKElIGHT GE 94

TAILLIGHT GE 161

FOR O PTI ONAL HIGH BEAM INDICATOR

IGNITION SWITCH

BRN

BlK

RED

BLU

OFF R U N START

~ o TO AL TERNATOR OuTPuT ~ Y ELLOW WIRE

~ -:- I~@NITIO: SW:CH--

/,/ G I / S

IGNITION SWITCH WIRE COLORS

G TERMINAL - BROWN

B TERM INAL - REO 8 M TERMINAL - BLACK

S T ERM INAL - BL UE 0

o TO IGNIT ION SWITCH I B TERMINAL)

f"j\ TO IGNIT ION SWITCH (S TERM INAL) \.V FOR ES AND DELUX E ONLY

TRAIL DELUXE ONLY --------

C\J .q-

C0

'<t (j) --CO

...Jcn «~ ocn a: 0.-t-cn 0 0 Wo ...JlI) W _

>8 ell) o -Cl8

v ~ 'C c:

E ~ C> C'O C C> c: .~

§ 0 0) 0) 'r"

I ;: 1 ffi

8 I ;: a: _ - z :, a: CD <L

CD IGNIT ION ASSEMBL Y

OFF

I

1°

ON

::; ~I I -----i

IGNITION SWiTCH

BRN

BRN

BlK

-=

LJ

IGNITION SWITCH

LOW

FOR OPT IONAL HANDWARMERS

W

RED

H IGH

GRN § YEL

YEl/RED

HIGH / LOW SWITCH

Y EL )

COLOR CODE

BLK BLACK BRN BROWN RED REO BLU BLUE YEL YE L LOW

0 ORANGE GRN GREEN W WH ITE

if ~ BRAK E LIGHT

SWITCH

z a: o

a w a: ::;

TEMPERATURE LIGHT IRED LENS )

YEL~ BRN ~ SPEEDDMETEF

YEL£) YEL BR;$ fACHOMETER

BRN

BRAKE LIGHT GE 94

BRN~ YEL~

H I , LO BEAM SWITCH

BRN -c:J FOR OPTIONAL HIGH BEAM

r----C:J INDICATOR o w a: ::; w >-

HEADLIGH

"<t Cl OJ

C") ~ C")

.2 en en co U o o Lt)

~ 'C e

...JE «E UC) - co 0: .-1-0 UC) We ...J 'i:: W,-

>3: co 00) m~

CO LOR COD E

BLK BLACK sq ,\. 8ROW"J

RED RED

BL U BLUE YEL YELLOW

0 OR A .... JGE

GRN Gq E E '\)

: , ~''; r-l IT E

BRN

BLK

RED

BLU

STATOR

I

1 [ 0"' ~

co

I

CO IGNITION ASSEMBLY °1 ,

OFF RLJN START

~ IGNITION SWITCH

BLK

IGNITION SWITCH

// G G I / S M

HANDWAAMER

ACCESSORY LIGH T

LOW OIL LEvEL SENDER

~---------------- BRN • L--f

Ie VEL ) I IGNITI ON

,W"O" ~ w ~

BRAKELIGHT SWITCH

OIL LIGHT IRED LENS )

()

TEMPERATURE LIGHT IR ED LENSI

"'--B SPEEDOMETER

YELU YE L BAN * TACHOMETER

BRN

TAILLIGHT GE 161

8RAKEUGHT GE 94

W~ I~I AUXILIARY SHuT -O F F SWITCH & THROTTLE

SAFETY SWITCH

b ~BRN~

YEL~ TAILLIG H T

GE 16 \

BRN

+ 12 V BATTEHY

-=-WIRE CO LOR

G TERMINAL - BROWN GROUND

8 TERMINA L - RED _ BATTERY

M TERMINAL - BLACK - IGNITION

S TERMINAL - BLUE - STARTER

STARTER R E LAY

2 a: co

HIILO BEAM SWITCH

r-=D o ill

§ W >-

HIGH BEAM INDICATOR

{BLU E LENSI

HEADLIGHT

~ ~ ('i)

'<:t O'l 00

..JCJ) <~ (,)CJ)

0:0 I-Lt') (,)(0 W~ ...J'O W.E >- . Ce o~ co ...

C) ~ c C) c

'a:: ~ o 0) 0) ,...

( \

V

o w a:

;:

" ...J

'"

z a: '"

YE L

BLK

u

FDA OPTIONAL HANDWAAMERS

( YEL 1

BAN

BAN

IGNIT ION COILS

IGNIT ION SWITCH

W

RED

rra ~ 11

w BRAKE LI GHT

SW ITCH

o AUXIL IARY SHUT·OFF SWITCH & THROTTLE

SAFETY SWITC H

'-------- BRN ------ - --------l

COLO R CO DE

BLK BLACK BRN BAOWN RED RED BL U BLUE YEL . YELLOW 0 ORANGE GRN GREEN W WH ITE

o

z a: (:J

o w a: :J

TEMPERATURE LIGHT IRED LENS )

H'.=8 SPEE DOMETER

VEL£) YEL BR~ TACHOMETER

BRN

B RN ~ YEL~

Hl i LO BEAM SWITCH

TA ILLIGHT GE 161

BRAKE LIGHT GE 94

TAIL LI GHT GE 161

BAN -c::J FOR OPTIONAL H IGH BEAM

r-----CJ IND ICATOR o w a: :J w >-

HEADLIGHT

<::t (J)

CO

L.()

~ (Y)

~ co .j::..

w ~ (J)

COLOR CODE BLK = BLACK BRN = BROWN RED = RED BLU = BLUE YEL = YELLOW o = ORANGE GRN = GREEN W = WHITE

S 0:

~ III

~

it I C.D. IGNITION

ASSEMBLY

BLK

STARLIT E

::Ir ON,

IGNITION SWITCH

OPTIONAL HANDWARMERS

L----~L-------L--------------YEL (

IGNITION SWITCH

BRAKEUGHT SWITCH BRN ~ ~-;

BRN ~ l SWITCH & THROTTLE ~ .... --- BRN SAFETY SWITCH P AUXIUARY SHllT.oFF

BRN

,

0\ CO IGNITION ASS EMBLY

I N DY LITE

I \0

LOW HIGH

GRN§ YEL

YEl/RED

HIGH/ LOW SWITCH

BLK I'BlK

1

7

BRN

Z 0:

"

o \oJ 0:

J '" ,.

SPEEDOMETER (OPTIONAL ON

STARUTE)

TA ILUGHT GE 161

BRAKEUGHT GE 94

BRN ~ TAILUGHT YEl~ GE 161

HIGH/ LOW SWITCH

HEADLIGHT

u

"""'OJ (00 ~O :E-< _. m :!. r::1m (Co 0-4 _. JJ ~(CO .,» ~r-3

en -~ :!. ;::::;: ~CD

::1 Q. '< r--CD

.....It<t~ 2t:: 0:0 t-c. 0(1) w ~ .....It:: WO >-c. c(l)

o~ me

E ~ C> ,~ C C> C

'i::

~ ,... 0) 0) ,...

COLOR CODE BLK = BLACK

BRN = BROW,", RED = RED BLU = BLUE

YEL = YEllOW o = ORANGE

GRN = GREEN W = WHITE

til 0:

~ .,

~

~ ex: '"

z ex: .,

~(r ON,

IGNITION SWlTCH

BRN

BLK

"='"

FOR OPTIONAL HANDWARMERS

YEL~ BRN ~ SPaOOMETER

Y~l YEL - BRN TACHOMETER

--A\..J..- BRN (OPTIONAL)

YEL \ I

IGNITION SWITCH ~~

JiW BRAKELIGKT L--4'--- BRN It , SWITCH

• I AUX ILIARY SHUT-OFF SWITCH & THROTT1.E

SAFETY SWITCH

BRN--------------~

GRN sLOW HIGH

YEL

YEL/RED

HIGH/LOW SWITCH

BLK

u

z ex: <:>

BR~ YEL-':'

HI/LO BEAM SWITCH

BRAKEUGKT GE 94

HEADUGHT

~ (J)

co

I"-7 C")

..JI«e" Ut: a:o 1-0-UCI) W ~ ..Jt: WO >0-cCl) o~ m-g

E «l ... C)

"~ c C) c:

"i: § .,... 0) 0) .,...


BRN = BROWN RED = RED BLU = BLUE

YEL = YEllOW o = ORANGE

GRN = GREEN W = WHITE

fil a: ...... :s CO

~

~ a:

'"

z ex: CO

~Ir ON,

IGNITION SWITCH

FOR OPTIONAL HANDWARMERS

m--rC\ BRN ~ SPEEDOMETER

Y~t BRN TACHOMETER

--AL.l..- BRN (OPTIONAL)

YEl. , I

IGNITION SWITCH ~~

BRN .. I It ~ BRAKEl.IGHT L..-.-Jf'I .... _-- BRN : i ~ SWITCH

BRN------------~

BLK (.

GRN sLOW HIGH

YEl.

YEl/RED

HIGH/LOW SWITCH

BLK AUXILIARY SHUT.oFF SWITCH & THROTTlE

SAFETY SWITCH

u

z ex:

'"

HI/LO BEAM SWITCH

BRAKEUGHT GE 94

HEADUGHT

.qOl ro

I".q-C')

~ U) .j::>.

w ~ co

COLOR CODE

BLK BLACK BRN BROWN RED RED BL U BL UE Y EL YELLOW 0 ORANGE GRN GREEN W WH I TE

PU z PURPLE Bl U/RED 2 BL UE WIRED TRA CER

SLK/W " BLACK W!WHI TE TRACER

RED/W .. RED W/WHI TE TRACER

~

Y EL

~ z Iii

JK

-=

HANOWARMERS

BI~N

LOW OIL LEVEL

SENDE R

TEMPERAT URE LIGHT

d] FOR OPTIONAL SAN ACCESSORY

UGHT ~BlK/AED _ ISUP EATAAKONL YI

SPEEDOMETER

Y EL~

BL U/ RED-------____ ...J §()

YEL

( BRN W ~ BAN TACHOMETE R

d YEL) I

IGNITION SWITCH

~"" ~ II I ~ TOFF

' ~BRN -RrAUXll1 AA~~~~TTLE ,"" "D '"!,I: I"., ""

~O BAAKEuGHT

SWITCH

." 0" BAAKElI G HT

GE 94

.L8AN~ TA ILLIGHT YEl~ GEI6l

---BLK r ~. BRN~

c.o . IGNI TION ASSEMBl Y

Off ON

::: [H-! ----i IGN IT ION SWITCH

LOW H IGH GAN§ YEL

VEL / REO

H IGH lOW SWITCH

YEL

~-w

REVERSE LIGHT

SWIT CH

SHIFT POSIT ION SW ITCHES

REVERSE LIGHT

BRN z ::;

y

f=D H IGH BEAM INOICATOA

HEADLIGHT

..... to COo ~C :e-< _. m ~ .. ::1m (Co c~ _. ::xJ cu_ (CO ..,» cu. 3

::I a. '<

:e a: Cl) ~ @

'"

..J":':: «ro (.,)t= - '-0:(1) I-Q. (.,)::1 wtn ..J ~ w(1)

>< >::1 0Ci) 00 m~

E I-~ '0 r:::

E E C)

. ~ o C) r::: .~

§ '9""

en en '9""

u

COLOR COD E

BLK '" BLACK

BAN BROWN REO REO BLU BLUE VE L YE LLOW o ORANGE GAN '" GRE EN W WH IT E PU PURPLE BlU/ RED · B L UE WI RED TRACER

Bl K/W " BLACK W/WH ITE TRACER

RED/W" RED W/WHITE TRACER

OFF

IGNITION SWITC H (STA NDARD)

TRAil & SUPEATRAK ~

RUN

BAN r-' -----1 BL K •

GAN

VEL

YEl/RED

LOW HIGH

§ H IGH / lOW SWITCH

8 -

IGNITION SW tTCt-l

BAN - --- -

VEL

~"' ~ . BLK ~ ISLK AUX ILIA R Y SH U T-OFF M SW ' TC H '" THAOTTLE

BL~ SAF E TV SWITCH

BA N

~ O BA AK ELI GHT SWI TCH

o 0 _____ _ ____ _ , --1 I -T AEO/ W ---, ,

AEO n"~ ,

OFF AUN STA Rr

BAN~ BLK

nED

AEO/ W

7

I , I I I I I I ,

~ TO AL TEANATOR OUTPUT _ YELLOW WIRE

2 TO IGNI TIO N SW ITCH ( 6 TERMINAL!

3 TO IGNITION SW ITCH IS TE RMINAl! ~~ElUXE~Y FOR DELUXE ONLY

ACC ESSORY LIGHT

YEL-----£\,: SPEE DOMETER B AN~

H IGH / LOW SWITCH

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W WHITE

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bCRIINK CIISE TEMP . SENSOR ~y BLU--

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KI LL SWITCH

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GN§LOW HIGH y •

Y/R •

H IGH LOW S ""I TCH

I

Ii"

BR or~F AUN START G

6K M

R B

A/iii 5

IGNITION SWITCH

u

BLK'R

BA

I 11.-------

I

SPARK PLUG

n' .. JM6WARMEAS

REGULATOR ( LR 8 1

CHASSIS GND

rpu

y--

i ,BLK"

LOW OIL LEVEL SENDER

O IL LIGHT IRED LENS I

TEMPERA T~E LIGHT IRED LENS I

'~ 5PEEOOt.4ETER

au Ace . LIGHT =- y "~~~..L" ct'~ -==fb Aee , ENG I NE GNO :: TAefQ<ETER

~BR I

IGNITION swl reH

~ ______ _ , BRAKE LIGHT ct!=0 r n S WITCH o

~~O ~DEA

1 puw

BA I r r rli-r== BA i IrR 8 1

BLK

BA ')

BLK ') ') ') ')

ijK

AUX I LIARY SHUT OFF SW I TeH ~ THROTTLE

SAFETY SW I TCI-!

SPARK PLUG L-___ AW _ ____ ....

REeT IF!EA

TA I L LI GHT GEI6 !

HEAD LIGHT

IGNITION SWITCH ENGINE GNO COLOR CODE 5T ARTER RELAY

CHASSIS GNO

1M IB IG

~ Is

IGNIT ION WIRE COLORS G TERM INAL BROWN· GROUNO B TERMINAL REO - BATTERY ~ TEAJ.4i N"L BLACK - I GNITION 5 TERM I N"L REO/ 'NH I TE - STARTER

6lJ( BLACK

BR : BROWN

BR' W : BROWN WITH WHITE TRACER

BLK'\R " BLACK WITH REO TRACER

BlK\W : BLACK WITt-! WHI TE TRACER

Y\.R " YELLOW WITH REO TRACER

BU'\R : BLUE WITt-! REO TRACER

R/ W " RED WI T t-! WH I TE TRACER

Pl!\.W : PURPLE w ITH WHITE TRACER

au : BLUE GN : GREEN

W , WHITE o " ORANGE Y : YELLOW PU " PURPLE R : REO

ENG I NE GNO ~

B .... TTERY

ENGINE Gr-D

q-0)

co

r-eo C0

.::t:. ctl ... IQ)

"0

ENJI~ 9'4J.

~ ~ "0 s::

..JE <ctl 00, -ctl a:: .-1-0 00') Ws:: ..J .t: W,-

>3: ON 00) m~

eu<'"

r-~~--------- M

ACCESSCJ<Y SWITOi

AEllLl..A"Tm

,~

-:;-

o-v.ss I 5 C3K).

eu<

IGNITI~ 51I'lTo-t

eu<

LOW OIL L..EVel. SE>VE:R

PU Fi:b OIL LIGHT

IIA

,. y

TE>f'ERA'l\JRE LIGHT IRED LENS}

~ ~M ~U. J~

eFVJ<E LIGHT q t o sw I Tot o

p ----- --------------~ I I

I I I I I I I I I I I

"UXIL IIVtY SHJT ()Il"'" I s.' 1 TQ-f & T't-AOTTl...E I

SAFETY SW I TCH 1

TAOO£TER

~ M ( I I I

eu< c' c' ~ __ ~ ____ ___ _________ 1

~.

SPI\AK P\..I.o

SPfoPK PLU3

y~ C<l..(>" COOE REVERSE

eu< • OLAO< M'fc1.~ IIA "".-6R\.W 11 eAJWN WI n-I 'IH I TE TRACER .. . 6lJ('\R " eL\O( • I n-I RED TRACER REVERSE L I eHT

eL.K'\.W 11 et....ACK Wln-I WHITE TRACEFI

~ " YB..LOW WITH RED TR.N::ER

el.J\.R " et..LE WITH REO TRACER ou • "'-L£

-:- ON • GREEN

El'«J t i'£ at-D. W If WHITE o • aw«lE y • Ya..LOW

PU • PIR'l.E

:II ~ IEitHTl~ SWITCH ~§

HIBH LO'I' SWITO-t

-eR-{l]

ttlf;' I-£AO LIOHT

HIGH lI£AW tr-DICJo.TCA

T/dl.../5A...A.KE L1eHT OEllS7

N CD C'0

'<t e: CO

w CJ) w

co W .p.

eu<'" ,--------<GR

if:: I .

I I I I I I

ENGINE GNO

BLK"'~ II

()

STATOR

BR

I

THU~6WAR~ERS

n

b l M ,

~ r=~~ I:1l ACCESSORY

SWITCH

REGUL ... rOR


n

OIL LlGHT (RED LENS I

TEMPERATURE LIGHT IRED LENSl

"=8 BU-==f1l ACC . LIGHT -=- a y ~SPEEDO"ETER ~ EN~INE GNO;R

~ ~

CHASS!S GNO

lGNJ TiON SWITCH

BRAKE LIGHT rR--O

SWITCH ~O

r------------------,

BR ~ , eR , ,

eLK AUl,) \\LH! "6,TYTHSRHoUrTTLO[F :

~ SAFETY SW ITCH eLK

OR ----- ------,

TACHOMETER

TAIL LIGHT GEIBI

,-------- BLK C -----------------,

:: Ii' ON

IGNITION SWITCH

SP"RK PLUGS

ENG!NE GND

'G;~\ Y/R~

HIGH/LOW SWITCH

IGNITiON COILS

'::'

COLOR CODE

BlK = BLACK

BR : BROWN

W'R : WH' TE WT! H RED TRACER

BLK\R : BLACK W [TH REO TRACER

BLK\W : BLACK WITH WHITE TRACER

VEL'R : YELLOW W [TH RED TRACER

BU'R : BLUE WITH RED TRACER

au : BLUE GN : GREEN

W = WHITE o : ORANGE Y : YELLOW PU : PURPLE

- eR-----ill

I" tU;; HEAD LIGHT

HIGH BEAM INDICATOR

n

..... CO CO J\)

~ ::::!. :::s

COOl Co -. C ~-< ~ Q)

3 m rm (")

:::S-4 c.J:J '< -0) (") (11» o r-

en ~ en ...J >< a: ~ 'C e:

...J E «~ (0) -~ a: .-~O (0) We: ...J 'i: W·->3: ON 00> al~

-:

,-____________ L-____________ BR

I :li

SPARK PLUGS ENGINE

GND

IGNITION COILS

REGULATOR

~

"

HEAD LIGHT

HANDWARMERS DUAL HEAT

TEMP . LIGHT

rEMPERA TURE SENDER

." ~NG I NE BK / .... ...J . GNO

B II [BRAK E L IGH1 r BR [[ rr [r I ~~ SWITCH ~

GNq

Y:R[±tj HI/LOw SWITCH TAIL

LIGHT GEISI

BRAKE LIGHT GE9 4

TAIL LIGHT GEI6 1

TACHOMETER SPEEDOMETER

LOW OIL LEVEL

SENDER

Oil L IGHT

,-----------------8K

, , I K ILL SWITCH :

I BA-~ QNTAOL I SPEEONCCE SW. 12 1 I ASSURA I

OK ,

IGNI TI ON SWI TCH

CIRCU i T BREAKER

, j ~ I LeK , ENGINE ~ ___ ;____ R~W ~eK!!2 ~ GND I ---- BR "

EFI RELAY

IBROWNI

SELF SHUT OFF RE L"Y

IBLUE I

FUEL RELAY IBLUE I

,-------R/W

i1i~.

33~

~~IOS'yj

I N,.H I INJ f 2

R ________ ~I-R J' , .... JX eA TTERY 16K I SERVICE PLUG

:==G,;::U .".n ~1f ~ ~l~ i:!~m:, rus I BLE L I">JK @oo W:: R;LU ~ OR ~ ~s~K-' COLOR CODE

BK ' BLACK CRANK CASE TEMP . SENSOR

LON LGN/6K

~~';;'~~~I POSITION SENSOR

II INJ '3 (I) II

6K / W ! BLACK wITH WHITE TRACER BR ' BROWN BR/ W , BROWN WITH WHI TE TRACER GN , GREEN GN/R ' GREEN WITH RED lRACER GN/W , GREEN WITH WHITE T,ACER GN/Y , GREEN WI TH YELLOW rRACER GY :I GRAY BLU ' BLUE

AIR TEMP , SENSOR

BK BR R

R/ W

KILL SWITCH m I*r~W~ l ~~ .=f] . II II (------1"' I I I t~~~~K BLU/ BK , BLUE WITH WHIT E ELACK TRACER

BLU/W , BLUE WI TH WHITE TRACER BLU/Y , BLUE WI TH YELLOW T9ACER LGN , LIGHT GREEN LGN/BK , LI GHT GREEN WITH IlLACK TRACER LGN/R ! LIGHT GREEN WITH REO TRACER o ' ORANGE P , PINK PU ' PURPLE R , RED R/BK ' RED WITH BLACK TRACER R/ BLU ' RED WI TH BLUE TRACER R/W , RED WI TH WHI TE TRACER R/Y , RED wI TH YELLOW TRACER W , WHITE W/BK , WHITE WI TH BLACK TRACER Y , YELLOW Y/BK , YELLOW WITH BLACK TRACER

Cfl" ON

IGN ITION SWI TCH

BRm BK R/ W Y/ B

"" ON

LO

u z (f) z 0

a: 0 a: f-« f-

...J U ...J U W 0 W W --, Il.. ...J :J Z W LL

""" to C0

"<t (J)

00

...JJ«CJ 0--~ a: .-J-...J Ot-"' WCJ ...J"Q) W_ >::i c ... o~ mC/) ~ 'C c:

E E C)

.~ c C) c: .t:

~ C'? 0') 0') .....

t\; £7 Y'A

Y

- *--=-

ENGINE GND

BA

CO l MODULE CU 620 ..

BLK\R

BR\ W

s rARLlTE , GT

OFF ON

::1 !-+-I ------1

r BA

-=-SP"RK PLUG ENGINE GND

IGNITION SWITCH

v

REGUL .... TQR

-=-ENGINE GND

FOR OPT I ONAL H ..... f\l)WARMERS

I c' Y --------------1

IGNIT ION SWITCH

BRAKE LIGHT r--r-r----o SW I TCH '----i L-Y

BA ~BA IrA P I

BA ------------, BLK c'

SPARK PLUG

BLK ijK "UXI L IAAY SHUT-OFF 5 W ITCH & THROTTLE

SAFETY sw ITCH

'=€) SPEEDOMETER (OPT I ONAL sr"RLITE I

HI LO BEAM

BA

--- ----~

r -;rARL JTE 6T :

i L ::p® i I _ 0 I

I

I I -- BA I

BRAKE LI GHT 6E94

BA~ TA I L LIGHT 6E I61

SPARK PLUG COLOR CODE

BlK :: BL"CK

BR :: BROWN

BR\ W :: BROWN WITH WHITE TRACER

BLK'-A :: BL" CK WITH RED TRACER

Y\.R :: YELLOW WI TH RED TRACER

GN :: GREEN

SR I Y\R

I ~ INDY LITE, 6T

GN~ Y/:L=±j

HI GH/LOW SWITCH

u

= ENGINE GND

HEAD LIGHT

W WHITE a :: ORANGE

YELLOW

u

'<t

~

L.() CD C')

~ to +:>

w m m

COLOR CODE

eLK = BLAC1<

SR : BROWN

-:

ENGINE GND .

BR'''''' = BROWN WITH WHITE TRACER

8LK\A = BLIICK WITH RED TRACER

Y'-A = YELLOW WITH REO TRACER

BLU,\R = BLUE W! TH AED TRACER

R\W : RED WlTH WHITE TR ... CER

GN : GREEN

W = WHITE o = ORANGE

Y = YELLOW

R = REO

REGU..ATOA

CH"SSIS GND.

.y",

BA

BLK'R

ACCESSORY SW I TQ-t

IGNITION SWI TCH

LU\R y=8 SPEEDOMETE R -BA

L-_____ BA ~

B~EIT1:~GHT q 0

~--------------------, I n I I I I I

BA

TAIL LIGHT GE I BI

,----0--- BA I < R LL-- BA i 'r===t'l I I

BA

~ BA (

,----- BLK ( ( ( (

SR\W

INDY LITE DELUXE

BA OF~F AUN STAAT G

BK M

A B

A/W 5

IGNI TION SWITCH

SPARK PLUG

SPARK PLUG

ENGINE GND .

I GNITION SWI TCH WI RE COLOR G TEAM ! NAL - BROWN - GROl.NO B TERM I NAL - REO - BATTERY M TERMIN ... L - BLACK - IGNITION

RECTI F IER

5 TERMINI\L - REO/WHITE - STARTER

BI\TTERY

ENGINE GNJ.

r AUXILIARY SHUT OFF S W ITCH 6. TtflOTTLE

SAFETY SWI TCH

.-------------------- ~

AW-----..,

51 ARTER REL ... y CHI\S5IS GNO .

ENG I NE GNO.

HI LO BEAM

BA I Y'-R

I ~ HEAD L I GHT

:N~ y",C=fj

H I/LOW SW I TCH

-(D (00 ~C :e-< -·m :!. r:::lm <0(") c-t _. :I:J Q) <0(") -t» Q)r-3

:::l a. '< r-;::;: (I)

C ~ c: >< (I)

...J't «0 uo-CI) a:~ 1-"0 Us::: w...J We >«1 c"'" o~ m'e

C) r::: .~

§ CO) 0) 0) ,..

REGULATOR

-=-CHASS I S GND

Il>"\' Y

ACCESSORY SWI TCH

HANOW ARMERS SINGLE HEAT

SA:=1]1 Ace. W/ 8LU L I GHT

BRAKE L IGHT

'=B SPEEDOMETER

:R£\ '------'-----BR~

TACHOMETER (OPTI ONAL) Ji§; *1*) Y\R I ( y ') ') I

-=-ENG I NE

GND

u

BR

BLK,\R

.---+------------BR

BR

~ BR ---------------,

W BA\W

OFF ON

:: 11+--I -----l IGNIT ION SWITCH

3LK (

SPARK PLUG

-=-ENGINE

GND

SPARK PLUG

GN~ V:RC:::=ij

HI /LOW SW ITCH

u

COLOR CODE

BlK ::: BLI\CK

SR ::: BROWN

SR\, W ::: BROWN WITH WH I TE TRACER

BLK ,\R BLACK WITH RED TRACER BLK \ W BLACK WITH WH ITE TRACER

YEL '\R YELLOW WITH REO TRACER

BLU,\R BLUE WI TH REO TRACER

W,\BLU WH I TE WI TH BLUE TRACER

GN ::: GREEN

W WHITE

o ' ORANGE

Y ::: YELLOW PU ::: PURPLE

o

IGN ITI ON SW ITCH

BLK

AUX I L I ARY SHUT OFF SW I TCH & THROTT LE

SAFETY SW ITCH

~ (I BR~ TArL LIGHT GE 16 1

~BR I ) BR====fl'

H I LO BE!l.M

HEAD LIGHT

TAIL LIGHT GE 161

u

'<t ~ CO

f'... <D CY)

~ <0 .j::.

w OJ 00

-::-ENG I NE GND

STI\TOR

\~\\\t\\" )d./7 Y'R Y

REGULATOR

~MB WARMERS -- ---- --- -- , OPTlQNI\L __________ .. :

ACCESSORY SWITCH

BLU\R

I I I

F,SI'. ! TEW . S~~

LOW 0 I L LEVEL SENDER

ENGINE GND

-::-

BR

BR~ ACC. W/ 6 LU LIGHT

CHASS I S GND BRAKE LIGHT

TEMPERATURE LIGHT IREO LENS)

'=B SPEEDOMETER

) ~£\ BR~

TACHOMETER

I ( y) ) I

BR

8LK\.A

,.--"------ BR

BR

~ BR --------------,

W BR\ W

: Ir ~ IGNIT ION SWITCH

BLK (

SPARK PLUG

-::-ENGINE GND

~§ HI GH/LOW SW I TCH

SPARK PLUG


SR = BROWN

BA\.W : BROWN WITH WH ITE TRACER

BLK\'R = BLACK WI TH REO TRACER BLK \.W : BLACK WITH WHITE TRACER

Y,\R = YELLOW WITH RED TRACER

BLU\R : BLUE WI TH RED TRACER

W~LU : WH J TE W J TH BLUE TRACER

GN ~ GREEN

W WHITE a = ORANGE Y = YELLOW PU = PURPLE

IGNITION SWITCH

BLK

BR

BRAKE LIGHT r-A=g SWITCH ~y

BR

I\UX ILil\RY SHUT OFF

BLK SW I TCH c!. THROTTLE ~ SAFETY sw ITCH

--- ------------------~

Y ) - UW=!!

~~TGE9' Y BR

TAI L LIGHT GEI6l

~BR

j"~ HIGH BEAM INDICATOR

I-EAD L I GHT

.... m <00 ~O :e-< -·m ::!. , ::::Jm

<C(") 0-4 _. JJ ~ -

<C(") ..,» 3' ::::J a. '< -4 .., ~

~

-4 .., ~.

0 ~ c: >< (l)

...Jcn «~ ocn a:ci i-oo::t o~ W~ ...J'C We: )-,

cE O~ lll'-

C) ~

C C) e: 'i::

§ M 0) 0) '9""

-=-ENG INE GND

( I

V

\\%s%i; I "A

- -)

BA

6LK'R

BA

IGNITION SWI TCH

r---- ------ ------ -- --

A

BA ~ BA I: 'r==-t' l

BLK

BA -------------------,

ijK

AUX [ L t ..... AY SHUT OFF SW ITCH cS. THROTTLE

SI\FETY SW I TCH

,---------- BLK ~

W 8R\W

SPARK PLUG

-=-ENGINE GND

:Ir ON

IGNITION SWITCH ~§ HIGH/LOW SWITCH

u

SPARK PLUG

COLOR CODE

BLK :: BLACK

SR :: BROWN

BA\ W :: BROWN WITH WH ITE TRACER BLK \ R :: BLACK WITH REO TRACER BLK\W :: BLI\CK WITH WH ITE TRACER

Y\R :: YELLOW WITH RED TR!\CEA BLU'\.R :: BLUE w ITH RED TRI\CER

W\BLU :: WH I TE WITH BLUE TRACER

GN ' GAEEN

W WHITE o :: ORANGE

Y :: YELLOW PU :: PURPLE

TAIL UGHT GE161

HI La BEAM

- BA-----fll

t tlf;' HEAD LIGHT

HIGH BEAM INDICATOR

en CD (")

~ <0 .j::>.

w ~ o

""'1' y

THUM6W f\RMERS ~SR

BLV'\A

l t=:t~ 1'-

REGi..LATOA

ACCESSORY SWITCH

-:-CHASSIS GND

BRAKE LIGHT

-:-ENGINE GND

2 ' BOR 'l'

TEMPERATURE LIGHT (RED LENS I

TACHOMETER

'l'b4~ ! Y' R _ _ } ( y ') ') 1

-:-

ENGINE GND

BR

BLK' R

W BR\.W

: Ir ~ IGNITION SWITCH

IGNITI ON SW I TCH

BRAKE L I GHT q 8 SWITCH

y

r--<>----- SR ~ BR:>I I~" ~

BR

BR -----------,

~ (

SPARK PLUG

SPARK PLUG

ENG I NE GND

GN~ V:RC:=jj

Hl/LOw SWITCH

COLOR CODE

BlK :; BLACK

SR :: BROWN

BR\.W :: BROWN WITH WH ITE TR",CER

BLK\'R :: BLACK WITH RED TR!\CER

BLK\.W :: BLACK WITH WH ITE TRACER

YEL'\A :: YELLOW WI TH RED TRACER

BLu\'R :: BLUE WITH REO TRACER

W/BLU :: WH I TE wITH BLUE TRi\CER

BLU :: BLUE

GN :: GREEN W :: WHITE o :: ORANGE Y :: YELLOW PU :: PURPLE

BLK

"UXIL!ARY Sh\JT-OFF sw I TCH 6. THROTTLE

SAFETY SW ITCH

, ~-----------------~

y J=BR===Q

~~TGE90 Y BR

TAIL LIGHT GE19 ...

-SR---fll

tUi® HEAD LIGHT

HIGH BEAM IND ICATOR

...... OJ COo ~O :E -< _. m ::l. r ::1 m <0(") 0 -1 _. J] Q)

<0(") @» 3 r

::I C. '< >< (") J]

...JCI) C:X:~ OCl) CI: -~ I-UOW WO ...JO WLO >~ 0'0 0'= tn'

E E C)

,~ o C) c:

'':::: § M 0) 0) '9""

REGUL~TQR CHIISS I S

1<1~--' GND

~

"

Y-- THJMBWARMERS

BLU

il/' , I BK--------,

I F BA ,, 55 ,5 BAt PU

OI L/BRIIKE DR LIGHT

BA GN

~

"

SPARK PLUGS ENGINE

GND . BK

HEAO LIGHT

Y/A

BR ±-------1

TIIIL LIGHT GEl61

HI BEAM

~--------- A/BK-------'


T"IL LIGHT

GE 1 6 1 (TEMP I BK/ W

TEMP/BATTERY WARNING LIGHTS

LOW OIL LEVEL

SENDER

POLARIS TO FUJI HARNESS I NTERCONNECT I ON

V I EW FROM THE BACK OF THE POLARIS PLUG

~----BA--------' " --------------~ -~ IBATT) BK/R1;j POLAR I 5 HARNESS a

O/lliBLK I CJl ~~I-L~-S-;"~;c~---------------~ 1 1~~nb8N 12V BATTe'RY I I

'BA~ , , , I SPEED CONTROL I I BK ASSURANCE SW. (21 I

R : ~ :

I ~ -==- : K : L-

~ -=- ~----------_-R/y __ B_R J ~~ O/BLK R/BLU (7) I@

r----------

.'i' ___ ,

SELF SHUT OFF REL~Y

(BLACKI

POLARIS HARNESS ~ -- ------ ---~ CO~~R ,C~~~CK . - FU~ I -H"AR-NESS - - - - • A/GN

BK/W :; BL ACK WITH WHITE TRACER R/ BLU ------ttb----R/BLU--.J GN/W:=!

~~/~ ~R~~~CK WI TH REO TRACER 1 .------Y/GNO/BK ~N---;)~---------r BK

------------------~----------------- BR

dGN~1

R/BLU

GN/BK

BR/W :; BROWN WI TH WH I TE TRACER

~~~A ~ ~~8~N ~ m AtbL?~~t~~CER GN :; GREEN GN/R ' GREEN WITH RED TR~CER GN/W :; GREEN WITH WH I TE TRACER GN/Y , GREEN WITH YELLOW TR~CER

GY :; GRAY GY/W , GR~Y WI TH WHITE TR~CER BLU , BLUE

AIR TEMP .

WATER TEMP.

SENSOR ~LU~E~/W;;;;;;;;;;~~hlj~~~llilJL~~~~~ BK / R ~ I GN/R - BK/W--1'-----------

SENSOR BR/Y

o/e Y /GN A/BK Y /BLU BA/y

"------------- -FU-.l I H~RNESS

BK/R

BK/W

ECU PIN • &. WIRE COLOR

, P/BLU 3 WH ITE , BLU/W 5 BLU/GN B GN/R

10 eK II D/BK

" Y/6LU IS Y/GN IS GN/Y 17 BK/y BLU/W :; BLUE WITH WH j TE TRACER

BLU/Y , BLUE WI TH YELL OW TR~CER BLU/G ' BLUE WITH GREEN TR~CER BLU/Q ' BLUE WITH ORIINGE TRIICER LGN ' L I GHT GREEN

II BA/y l...'==:....... I ~ /'SIR '_ SCI

L ___________ _ _ _ ___ BK GN/Y MONITOR

LGN/BK :; L I GHT GREEN WITH BLACK o :; ORANGE O/BK ' ORmGE WITH BLIICK TRIICER O/BLU ' OR~NGE WI TH BLUE TRIICER P , PINK P / BLU ' PINK WITH BLUE TR~CER

PU ' PURPLE R ' RED R/GN , RED W ITH GREEN TR~CER R/BK ' RED WITH BLIICK TRIICER R/BLU , RED WITH BLUE TRIICER R/W , RED WI TH WH ITE TRIICER R/Y :; REO WITH YELLOW TRACER W ' WHITE Y , YELLOW Y /R :; YELLOW WITH RED TRACER Y /BK , YELLOW WITH BL~CK TR~CER Y / BLU ' YELLOW WITH BLUE T RIICER Y /GN ' YELLOW WI TH GREEN TR~CER

u

TRACER KILL SWITCH

BK~ BR~

0I'l'" ON

BR~ I3N~LOW HIOH

BK c::.!:::D Y H3NTION' SW I TDi Y/R

~S.gI I3NITION SWI TOi Y/GN

BR

BK

RAt

R/BLU

HIILOW SWlTo-l

E . S. INFORMI\TI ON n-E WIRE PI.J.JG

COf>NECTOO NEAR THE IGNITION SWITOl 15 .... OA ELECTRI C START

YSE""-'

y:£ ~ I~IOI C1f1" (1<,1 START

u

U lJl Z Z

0: 0 0

< 0: -l t- t-

O U -l U

a.. W w W

-l :J ....,

W lL Z

u

P I N . &. WIRE COLOR

101 LGN 102 LGN/BK lOS GN/W 106 R/GN III BA 112 BA/R 113 P I" eR/Y 1 15 eR/Y 116 R/1lK 121 BA 122 BR/A 123 IlK/A I " 1lK/W 125 BR/Y 126 R/BK

u

"" (J) --CO

r-i"--C0

~ <.0

"'"

w -..,J I\J

ENGINE GND

OR

BLK\R

----BR PU OI L LIOI-nl UJ IREOLENS

THUMBWARMERS

AEGUL"rOA

-=-CHASSIS GND

r'[h M~U~ [" ~:e~,~ l OR LOW a I L LEVEL

~ " ~ SENDER I 'IT y

TEMP. LY TACHOMETER

ENG I NE GND BR

W IBLU..==f11 Ace", LIGHT

IGNiTION SW I TCH

~oo------~------~====~~

BRI\KE LIGHT #0 r-------~ SWITCH n I Y

OR

~--...... ---- BR ~ BA >==:r:..j

BR

BLK

AUXIL IARY SHUT OFF SW ITCH &. THROTTLE

SAFETY SW t TCH

~ BR--------------,

W BR,\W

:: Ii RW ST ARTI

IGNITION SWITCH

u

-=-ENG INE GND

GN~ V:RC==jj

HI GH LOW SWITCH

~ )

SPARK PLUG

COLOR CODE

BlK :: BLACK

SR :: BROWN

6R\.W :: BROWN W! TH WH ITE TAACER

BLK'\R :: BL"CK Vi ITH REO TRll.CER

BU(\W :: BLACK WITH WHITE TRACER

Y'\A :: YELLOW wI TH RED TRACER BL~ :: BLUE WITH RED TRACER

R/W :: REO WI TH WHITE TRI\CER PU'\W :: PURPLE WI TH WHITE TRACER

W\6LU :: WH 1 TE Vi J TH BLUE TRACER

BLU :: BLUE eN :: GREEN Vi :: WH ITE o :: ClRANGE Y :: YELLOw PU ' PURPLE A :: RED

u

..... [0 COo COo (..)-< :E - · m :::!. r-::s m

<0 (") o-t _. ]J al_ <0(") @ 3

::s c. '< (") al en en O·

» r-

..JO')

« .= 0'" -::l

~~ 0" W·-..J ~ Wro >-0 c~ 0-0 alr::

E ~ 0') ro C 0') r:: .i:

3E C"') 0') 0') '9'""

-:-ENGINE GND

6R

BLK\'R

THUMBWARMERS

ACCESSOAY SWITCH

REGUl.A TOR ! LA 8 1

r~pu y--

rBLK\'W


OIL LIGHT IRED LENS)

TEMPERA TUR£ L I GHT IRED LENSJ

'~ SPEEDOMETER

W/BLU Ace . LI GHT -= y '~~~~ " ct'~ :==fll ACC . ENG 1 NE GND:: "CHOMETER ~eR t -:-CHASS IS GND

IGNITION SWITCH

r---+---- 6R )) )1

6R

6R

6LK

BRAKE L IGHT ~o r-- - ----.. SWITCH a , n Y

6R

"UX IL IARY SI-UT OFF SW I TCH & n~OTTLE

SAFETY SW I TCH

I PUW

TAIL LIGHT GEIS I

~ 6R) ij"

GN~ yY/RL==jj

HIGH LOW SWITCH

6A OF§F """ START G

6K "

A 6

R/ W 5

IGNITION SWITCH

v

r-------- 6LK )) ))

SA''''''

SPARK PLUG

COLOA CODE

elK:: BLACK

SR : BROWN

SR'''''' : BRowN WI TH WH I TE TRACER

BLK'-R :: 8l./1CK wITH RED TRACER -= BU( \.W :: 6L/I.CK WITH WH ITE TMCER

IGN01T~ON ~WlTCH

I" ~ Is

IGNITI ON WIRE COLORS

ENGINE Gf'V

e TERM I NAL - BROWN - GROUND e TERMINAL - REO - BAnEAY M TERMINAL - BLAD< - IGNITI ON 5 TERMINI\L - REO/WH TTE - STARTER

u

Y'R :: YELLOW WITH RED TMCER BL~ :: BLUE WI TH RED TRACER

R/W :: REO WITH WHITE TRACER

PU\W ; PURPLE WITH WHITE TRACER

W\.BLU :: WH I TE WI TH BLUE TAACER BLU :: BLUE GN :: GREEN W :: WHITE o : ~J\NGE Y :: YELLOW PU :: PURPLE R :: RED

R R\W

RECTIFIER

-== 811.TTERY

ENG INE GND

u

ST/l.RTER RELAY CHASS I S GNO

ENGINE GND -=::-

HEII.O LIGHT

..q CJ)

CO

(V)

" (V)

~ (0 .j:>.

w -..,J +>-

ENGINE GNO . -:-

BR

srATOR

BLK \ R

!3R\W

:: II' ON

IGNITION S WITCH

·Y\R

BR

ACCESSORY SWITCH

REGl..LATOR ~T" CHASSIS GND .

BR (

BR (

BLK ( (

SPt\RK PLUG

COLOR CODE

BLK : BLACK

BA = BROWN

IGNI TiON SWITCH

REVERSE LIGHT

SWITCH

SPARK PLUG SA"'" : BROWN WITH WH ITE TRACER

BLK\R = BLACK WITH RED TRACER

6U< \ W = BLI\CK WITH WHITE TRACER

Y'-R -= YELLOW WITH REO TRI'ICER

BLU\R = BLUE WI TH REO TRACER

ENGINE GND .

~"~ Y\Rt:==ij

HIGH LOW SWITCH

GN = GREEN W = WHITE o = ORI\NGE

Y = YELLOW PU = PURPLE

BLK

w

PU

LOW 0 I L LEVEL SENDER

ENGINE GND. BR

BRAKE L I GHT q [ 0 SWITCH

Y

ijK

, , " UX IL I i\RY ShUT OFF r SW I TCH & THROTTLE I

S ..... FETy sw J TGH I ,

~~"'~ i

F=Dl OIL LIGHT

OR

U<\W ~ TEMPERI\TIJRE LIGHT IRED LENS I

I

'=8 SPEEDOMETER

~~ Ti\CHOMETER

L-=====::jc:rt§ ) Ti\IL/ BRAKE LIGHT GEI157

OR

PR

t~ HE"O L IGHT

HI GH BEAM INDICATOR

...... OJ COo ~O :E-< _. m ~. r ::::J m

CC (") 0-4 _. :D 0)-

CC ... 0)

3

::::J C. '<

51 c. <1> -4 @

"

(") » r

(;.)

-..J (J1

OJ (0 .j:::.

BR

ACCESSORY SWITCH

REGlA.../l.TQR

(")


"I?L B.~R---------L-------------------,

IGNITION SWITCH

BRAKE LIGHT

TEMF"ERA nJRE LIGHT IRED LENSI

'=8 I --+-~ ~SPEEOO"ETER

BR BR

rACI-004ETEA

i ~ M \L-_I °1_" __ _

SPARK PLUGS ENGINE

GNO

orc ON

::: f-t-II --i tGN'ITION SWITCH

IGNITION COILS

~R§ HIGH/LOW SWITCH

COLOR CODE

BLK :: BLACK

SA :: BROWN

SA' ,*, :: BROWN WI TH WH ITE TRACER

BLK'Jl " BLACK WI TH REO TAACER

6L!< \.W :. BLACK WITH WHITE TRACER

Y\.A :: YELLOW W r TH REO TRACER W\.R :: WH I TE WITH REO TRACER

BLll'A :: BLUE WI TH REO TRACER

W/8LU :: WH I TE WI TH BLUE TRACER

GN :: GREEN

W " WHITE a :: ORANGE

Y :: YELLOW PU :: Pl..ft'I . .E BLU = BLUE

- BR--nl H I GH BEAM

i~'~'~-

!-£N) L IGHT

(")

..... <0 <0 (.)

~ ~. :::l

(Q

C Q)

(Q

@ 3

OJ a :::lc 0.-< '< xm • ~m ~ C') en~ ~"tJ ~ enC') ,,» en.

Q:: CD ~

w ~ CJ)

REGULATOR HANDWARMERS DUAL HEAT

,-------------L--------------BA---------------1

ilj

SPARK PLUGS ENGINE

GNO

IGNITION COILS

ENGINE ~GNO

HEAD LIGHT

HANDWARMER SWITCH

W/BLU

GE I61 ~-------BI<-----------,

EF I SELF SHUT RELAY OFF RELAY

(BROWN I (BLUE I

CIRCUIT BREAKER

ENGINE _JLI~~=Ab~_m_ j ~ h~~b/BK GND ~A ,R1i 1 ~~~v~~~T~~~ LI --------1

BR

ACC . LIGHT

GE94 GE l 6 l

COLOR CODE BK ~

BK/ W

~ CF~~ A/W A/ Y

r, L J~~L-Pl ' RES ISTOR I

F US I BLE LINK W/ 8K R/ BLU I ~K-

BR ~ BR/ W GN ~ GN/R GN/W GN/Y

BLACK ~ BLACK WI TH WHITE TRACER BROWN ~ BROWN WI TH WHITE TRACER GREEN

WITH REO TRACER

GREEN ~ It~ ~~~~5WT~~xe~R GY ~ GRAY BLU ~ BLUE BLU/BK ~ BLUE WITH WHITE BLACK TRACER BLU/W ~ BLUE WITH WHITE TRACER BLU/Y ~ BLUE WI TH YELLOW TRACER LGN ~ LIGHT GREEN [~~~~K ~~ LT~~~TG~~~~NWf+~HR~bAf~At~~CER o ~ ORANGE P ~ PINK PU ~ PURPLE R ~ RED R/ BK ~ REO WITH BLACK TRACER R/BLU ~ RED WI TH BLUE TRACER R/ W ~ RED WITH WHI TE TRACER R/ Y ~ RED WITH YELLOW TRACER W ~ WHITE W/ BK ~ WH ITE WITH BLACK TRACER W/ BLU ~ WHITE WITH BLUE TRACER Y ~ YELLOW Y/ BK ~ YELLOW WITH BLACK TRACER

o

CRANK CASE TEMP . SENSOR

AIR TEMP . SENSOR

KILL SWITCH

BK m BR

R R/ W

CTF "" I GNITION S WI TCH Mm BK

R/ W VI

rI"f' ""

~ GA

~~r~~~_ l BK ~~ ,

U lfl Z

0 0:: < 0:: ....J I-

U ....J 0 W W 0.. ....J ::J

W lL

Z 0

I-U W ') Z

GNIR GN/Y

R LGN/ R LGN/ 6K

LG

BK

IN..Jf3

LGN/BK - LGN/R

TEMP . LIGHT

LOW OI L LEVEL

SENDER

THROTTLE POS ITION

SENSOR

TEMPERATURE SENDER

...A.CJ (0 0 ~ O :E-< -·m ~. 1 ::lm (Co 0-1 -. ::D Q)(CO @l> 3 1

::l C. '< ::D >< 1 ~

en ~ en

-I CI) «~ OCl) i%: I-E 0'" w.s -ICI) w~ >"0 Co!: O. mE

~ C') co ,-C C') c '':;

;: CO) 0) 0) .....

w SUVA

u

TH.JMBWARMERS

"CCESSOAY SWITCH

REGULATOR

-:-CHASSIS GNO

BR-----.--------------.---------------------~ OI L LIGHT

TEMPERA TUAE LI GHT I RED LENS I

"~dJl_ ~ [~': I J- W '-~ ,~,~ _ ,L1,£'1 LOW OIL LEVEL

SENDER

IGNITION SWI TCH

BAAKE LIGHT

SAME LiGHT q oO SWITCH

Y

BR~ TACHOMETER

TAIL LiGHT 6EI61

BR ~BR IrR B I

l BR------,

BLK

"UXILIMY 5HJT OFF BlK SW ITCH IS. Tt-flOTTLE ~ SAFETY SW ITCH

~----------------------- BLK ( ~------------------- - -- ~

HI LO BEAM

-:- -:-

SPARK PLUGS ENGINE

GND

: Ir ~ IGN I T I ON SWITCH

u

IGNITION COILS

GR~ yY/RC=jj

H I 6H/LOW SWI TCH

COLOR CODE

6L1< " 6L"CK

SR :; BROWN

SA' W :; BROWN WITH WHITE TRACER

BLK\A :; BLACK W [TH AEO TRI\CER

BLK\W :; BLACK WITH WHITE TRACER

Y\ R :; YELLOW WITH RED TRACER

W'R :; WHITE WITH REO TAACER

BLl1'A " BLUE WITH REO TAACER

W/ BLU " WHITE WI TH BLUE TAAGER

aN :: GREEN

W :: WH ITE

a :: ORANGE

Y :; YELLOW PU :; PURPLE BLU :; BLUE

u

-BR----fll tru;; HEAD LIGHT

H IGH BEAM I f'1.:)JC ATOR

"'" 0)

co

I'I'-C'0

t(!) -Q) :t::::: ...J

t-=' (!) -Q) :t::::: ...J ~

co -CJ)

...JE <C~ (0) -co a:: .-t-C (0) we: ...J 'i: w·->3: c~ ocn al~

STATOR

Q!> o

EN3Ir-E Gt-D

BLK'"

* ~~~ nu.e wAA><ERS

AEC3lJ.....ATCf{

ACCE~Y SWITCH

El'-G1f"E BN:I

BL~

IGNITION SWITQ-1

BRAKE LIGHT~OR SWITCH Y L-y

~---- ------- --- ---- ,

~ 5PEED(J.£TER

(CPT I CNAL ST ....... ITEI

----------------------~ ST.-..ALITE GT I

~ i I

~----------------------~

y 'i= eRN ----=1 (

TAIL LlGfT GE I61

~~/.-------- BAN ~ BAN 'r--==(, I

BAN

~ BRN---------,

,---------BLK (

COl .aJU.£ aJ 620<

BRN/W

STAALITE, GT

: Ir 0<

51'_ PLUl EN31t£ 61'..()

leNlTJCN SW ITCH

SPAAK PLl..O

H()Y LITE. GT

=§ HleHl'l..O'f SWITa-t

* SINGLE HEAT HANDWARMERS. THUMBWARMER. AND LOW OIL STANDARD ON LITE GT .

SPARK PLU3

e-Gir-E C3I'.[)

BLK

,"

~ AUX I LIMY SHJT 4 OFf' 511'1 TD-I & l"t-flOTn-E

SAFETY SW I TCH

L __________________ ~

COLOR cooe: BLK IlU.CK eRN _

BLU 8LLE OON GREEN PU\ PU1PLE OR C>W<ClE R RED W WHITE Y 'YELLOW TWO cct...OR • I RES /IRE. SH:lWN WITH ""'" I N/TRACE CCl..CRi. ElW#'LE' ~/R = eLLE WITH RED TRACER

HI UJ BEAM

eRN I'M

I~ t-EAD LIGHT

0::> r--... C')

~

~

-IQ> «>< oj -Q) ~e oQ> W~ -1-1 WI

> E em 00, r::a ,~

e C) c::::

'a::::

i v en en ,..

COLOR CODE BLK BLACK BRN BROWN BLU 8LUE GRN GREEN PUR PURPLE OR ORANGE R RED W WHITE Y YELLOW TWO COLOR WIRES ARE SHOWN WITH MAI N/TRACE COLORS . EXAMPLE: BLU/R = BLUE WITH RED TRACER

~ ~8LlJ\R

nUMB WARMERS

REGULATOR

"CCESSQAY SWITCH

HANOWARMERS S INGLE HEAT

~

~

OIL LI GHT

,.----Y----,

-::-CHASS 1 5 GNO .

LOW OI L LEVEL f---Y=€) SPEEDOMETER SENDER - SPN

~ 1'--1

~71 y~Y <&r @

IC y ------ ------l

~---- BAN ...l..fl, Ace . '-____ BLU/R ~ U L I GHT

ENGINE GNO.

u

BlJ(~

IGNITION SWITCH

BRAKE Ll GHT ri OR SWITCH Y

L-___ .J--- Y

----- - --, I I

.....---.--- M< I ~ R ~ M< ! I: -f==!=,

~ M< (

r------- BLK C C C C ORN/lt

I NOY LITE DELUXE

BAN ~OFF AUN STAAT G

e~K M

AIW

IGNITION SWITCH

SPARK PLUG

SPI\RK PLUG

-::-ENGINE GNO.

IGNITION SWITCH WIRE COLOR G TERM 1 NAL BROwN - GROUND B TERM I NAL AED - BATTERY M TERMINAL 6L!1.O< - iGNITION LI MI

Y

RECTI FIER

BI 51 G I

5 TERMINAL REO/'NHI TE - STARTER

B"TTERY -::-

ENGINE GND.

LJ o

BlJ( BlJ(

AUX I L I ARY SHUT OFF SW ITCH & THROTTLE

SAFETY 5W ITCH

RW-----...,

A

STARTER RELJ\Y CHASSIS GNO.

-::-

EN13 I NE GNO.

HI LO BEAM

M 00

(J) r'-C')

en ~ en -t: o Co en ... Q) Co :::s

en -t: o Co en

...JE «~ OC) -co a:: .-t-C OC) Wc:::: ...J 'i: W,-

>3: C~ 00) m~

• TH.M6WARMEA

REGUl..ATOA

LAB

O U~

-=-

BLlJ'.R-aF!lRtI

"CCESSORY SWITCH

CHASS IS GND

()

, t2%R2#v7 y~ y

ElfW(E LIGHT

I ( y ') ') I

-=-ENGINE ~

RN

BLK' R

IGNITION SWITCH

-------------------~ I I I I I I

,.---1...------ BRN ~ : BRN I

BRN

~-------~------------ BAN --------

~ (

BRN/W

:\r ~ IGNITION SWITCH

SPARK PLUG

-=-ENGINE

GND

SPARK PLUG

=§ Hl/LOW SWJTCl-i

CCl..OR CODE

eLK BLACK

BRN BROWN

BLU BLUE GRN GREEN

OR ORANGE

PUl PURPLE

A AED

W WHITE

Y GREEN

TWO COLOR WIRES ARE SHOWN

WITH MAIN/TRACE co....ORS EXMPLE . BLU/A • BLUE WITH RED TRACER

OPTIONAL ON SOI<E ..:lDELS

I I

BU< ~~+EA~y~~F' : ~ SAFETY SW I TCH j

I I

BLK

~ --- --------- -------.

• T AQ-K)METER

___ ~')",--=BRN-=--~

r"IL LIGHT GEI61

'----')H')OR ~

SAAKE LI eHT GE94

!lRtI

TAIL LlGKT GEISI

HEAD LIGHT

"..

a co C")

'<t

~

...I <t~ 21-a: I-E OCO wr... ...10> W .~ :>c co> 0.5 co .= ;: ~ 0) .,..

-: ENGINE GM)

u

TH....IMBWARMERS

REGlA..ATOR

~-ACCESSORY

SW ITCH

BLU~

T~----iY "j~


BAN

ENGINE GNO

'=-B SPEEDOMETER

-: Y BAN~ ACC .

L-- W/BLU LIGHT

I )~£\ B~~

CHASSIS GND l ' Y BFW<E

LIGHT TACHOMETER

~ §' Y'A _ *- } I < y ') ') I

BAN

BLK'\R

IGNITIC>< SWITCH

r---~----------BRN------------L-------------------.---J

BAN

~ BAN---------,

W BRN/w

:: IIF C><

IGNITION SWITCH

~ ~

SPARK PLUG

SPARK PLUG

-: ENGINE GNO

~§ HJGt-VLOW SWITQ-i

u

COLOR CODE

BLK BLACK BLU BLUE BRN BROWN GRN GREEN PUR PURPLE OR ORANGE Y YELLOW W WHITE R RED TWO COLOR WIRES ARE SHOWN WITH MAIN/TRACE COLORS EXAMPLE. BLU/R , BLUE WITH RED TRACER

u

BAN

BU<

r--- --------- -------- -- ,

,RN

~U< "UXIL l AAY SI-l.JT OFF SW 1 TCH & l'lflOTTLE

SAFETY SW I TCH

, --------.1

H I La BEAM

BAN

r ..... IL LIGHT GE161

~ j Y'A P I~

H IGH BEAM I/'() I C!l.TQR

>£AD L IGHT

o

'<:t 0)

00

T"""

CX)

C')

Cl)

>< ::l (i) o

f'! I-

....IE «f'! (0) -~ a: .-1-0 (0) We ....I '':::: W,->3: o~ 00) m~

-:-ENlINE Gf'()

CQOR COOE

BLK BLACK BLU BLUE BRN BROWN GRN GREEN PUR PURPLE OR ORIINGE Y YELLOW W WHITE R REO TWO COLOR WIRES lIRE SHOWN WITH MAIN/TRACE COLORS EXAMPLE, BLU/R ' BLUE WITH RED TRACER

nueWAR>ERS

RtGl...L\TOR

v-ACCESSORY

SWITCl-I

~ ~71 y

= -:?_ ""-ll ' , CHASSIS (N)

I I'

BAN

BU<\R

IGNITI ON SWITCH

r--+----- BAN ,), ') ') I

BRN

~ BAN ')

BLK ') (' ') ')

BRN/W

F'S~ LOW 0 I L LEVB...

BAN i_:~ W/BLU~ LIGHT

BIW<E LIGHT

BAN

6RAKE LIGHT rlR::~ SWITCH ~y

~LK AUX I L I AffY SH.JT OFf' SW 1 TCH 6. TIROTTLE

SAFETY SW I TCH

~------- ---- ---- ------- ~

'=B SPEEOOMETER

Y ')"": BAN ---==1 (

H I LO BEAM

rAIL LIGHT GEl61

HIGH BEI\M JI'D I CATOA

SPARK P\..UG L-----___ A' W __________ ~ ~ I Y\R P

z§ HIGH LOW SWlTo-t

BAN Of1'"~RLN START G

BU< " A 6

R/W 5

IGNITION SWITa-i

SPARK PLUG

-'--:-

IGNC0IT~ :ITCH ENGINE C3NO

IG f- Is

J GIN I TJ ON WIRE COLORS G TEA><INAL - AEO/WHITE - STARTER

Y

-::=: BATTERY

ENGINE Gt..o

STARTER REl.AY Q-{ASS I S GNO

El-G INE G!'o\) ':;:"

I~ f-EAO L IGHT

N CO C'?

'<;f" 0)

ro

..JCJ) «~ ()CJ)

0:-1-0 ()"d" w"d" ...I' wE >~ cO) o,~ mc

0) c: '\:

~ "d" en en ,..

o

.--------eRN -------r-------,

":" Y

~! Y c:w.ss I 5 aN)

L.OW 0 I L l.£VEL SEMlER

ENGINE aN)

!!RAKE LlaHT

TaI'ERA TU<E L I aHT (RED l.£NS1

y--rH'h---..

I ~ Y Y~

T...ao.ETER

I r' y ') ') I

1ll.J(\R

leNITION SWITCH

IlfW<E LlaHT rR ~ SWITai ~y

r----------------------, I I I I I

: rr: l.--.I ,--..... ----- eRN ! ~ eRN i F ~I

eRN

~ eRN---------------, ,...-------- IlLK C

Ill.J(

N.JX I L I AA:f SHIT f7r SW I Tai & Tl-flOTTL£

!W'E1Y SW I TCH eRN

" IlAWl' ~---------------eRN-----------------------~

~Ir ON

leNITION SWlTai

SP.-.Al< F'Ll.Q

":"

ENGINE C3Kl

~~ YIRC:=iJ

H II!HI\.OII SW I TCH

u

SP.-.Al< F'Ll.O COLOR CODE BLK BLACK BRN BROWN BLU BLUE GRN GRN PUR PURPLE OR ORANGE R REO W WHITE Y = YELLOW TWO COLOR WIRES ARE SHOWN WITH MAIN/TRACE COLORS. EXAMPLE I BLU/R = BLUE W nH REO TRACER

u

HIBH eEAW IHOlCATOR

__ -,eRN=:...~ GEG<

TAIL LIBHT GEISI

y

H leH/LOW I!EAM SW I TCH

L.OW !>EAM L IBHT YIR

!!AN

HI BH eEAW L IIlHTS

HEAD LlaHT

"<t (J)

ro

C") ex::> C")

a: o >< o o co

...IE «~ 00 - ~ a: .-.... 0 00 We ~ 'i: W,-)-3: o~ 00) m~

W

6U(/ R ca.

I" IlRN

6U( WI RES RESJSTMCE

BUU R TO R ".6 (;H,(5

W TO W/ R 100 ()H.t5

~~~y I 4:~0H.cS

nueWARMERS

ACCESSORY SWI TCH

REGU.....ATOA

~

CHASSIS Gr-()

LOW OIL LEVa. 5E>lJER

OIL LIGHT

'I=~': ~;~~ .U BRAKE LIGHT

TAo-o.E:TER

I ( Y ') ') I

IlRN

IGNIT ION SW ITCH

IlRN

BRAKE L IGHT ctE~~ SWITCH

Y

r - -------------- --- - - -- ~

AUXI L IAAY SHJT OFF SWITCH & llflOTTl£

SI\FETY SWITCH

BRJoJ<E L1 BHT GE9-.

Y BAN~ TAll LJGHT GEl6 1

6U( ( (

I '::" - -- -

SP/\RK PLUGS ENGINE

GNO

:Ir '"' 18f101ITIa-J SWtTQ;

-;-

IGNITION CO ILS

:§ HI eHIUJW SW I TCH

IlRN 6U( ,

I I :

co..~ CODE

BLK BU,CK BRN BROWN BLU BLUE GRN GREEN PUR PURPLE OR ORANGE R RED W WHITE Y YELLOW TWO COLOR W I RES ARE SHOWN WITH MIl I N/TRACE COLORS _ EXAMPLE. BLU/R ' BLUE WITH RED TRACER

! II TEll-ER SWITCH

.. ___ 6_~ _x~ _~Y ___ J t~ f-£AO L IGHT

HIGH BEAM ii'IJl CATOR

"<:t ~ C')

<::t

~

....10: «0 (J>< ([0 .-,V (JV WI ....IE w~ >0) c~ 00 £CO)

r::::: '':

i v en en ,....

ENGINE GNO

u

~! Y

nu.eWARlotERS

REC3LLATOO

ACCESSORY SWI TCH

-:-CHASSIS GNO

~TI.RE LIGHT IRED LENS!

,=€) '----------7-1-') I ----L-_ ~, .. ~~~~

00 I~:~ TACHOMETER

I ( Y ')')1

BAN

au<Vl

IGNITION SWITCH

BFW<E LIGHT ~g: SWITCH

Y

r----------- ---- -- , I I I I I

BAN

TAIL LIGHT GElS.

BAN

BFW<E LI GHT GE90

V BAN==---c(j:g>

TAIL LIGHT GElS.

"---+---BAN ~6RN ! r B I I I I I I I I I I I I I I I

BAN

~ BAN--------------~

r---------------e~ C W BRN/W

SPN'O< PLUG

SPN'O< PLU3

:;-

ENGINE GNO

::II ON

l eNITION SWITCH =~ HIILOW SWITa-i

COLOR CODE au< IlLID<

BAN • eROWN

et.....U z 61.UE C3RN , GREEN PU\ PU1PLE OR • 0RiII'alE

V YELLOW

.II WHITE R ,RED

TWO COLOR W I RES " SH:lWN WITH "'" I t</1"fV.a;; COLORS. EXAlf'L£I eLU/R • et..IJE WITH RED TRAC ~

au<

~---- --------- ----~ HI LO BEAM

r+T + ~ ~ HEJ\O LIGHT

HIGH 6ENoI I~ICATOR

~

~ 00

L{) CO Ct')

a. en a: o >< o o::!' o::!'

..JE c:cE (0) -('0 a: .-t-C (0) We ..J 'i: W ,-

>3: Co::!' 0 0) m~

THUMBWARMERS ~1BRN BLU'-A

l ~ ~t~ I I::1l LK\.W

TEMPERATU<E LIGHT IREO LENSJ

LOW OIL LEVEL I v=B REGULATOR

ACCESSORY SWI TCH

-::-

SENDER - BRN

SPEEDOMETER

E7~~ .-L ~ Y~ ENGlri GND ~

~------------~)~----~----BRN . ~ OR -----------,

\\\;--;_%)' Y'R~ CHASSIS GND

TI\CHOMETER

-::-ENGINE GNO

BRN

BLK\.R

IGN ITI ON SWITCH

r---~-----------BRN -------------------L---------------r--~ ~BRN

BLK

~ BRN------------------,

W BRN/ W

: \r ~ I GNIT I~ SW ITCH

BLK (

SPARK PLUG

SPARK PLUG

-::-ENGINE Gi'()

~§ HJI'LOW SWITOi

COLOR CODE

BLK BLACK

BRN BROWN

BLU BLUE GRN ;; GREEN Pm , PU<PLE

OR ' ()RAM;E

Y YELLOW w WH ITE

R ' RED TWO ca...OR WIRES ARE SHJWN

WI TH """ I N/TRACE ccx..ORS. EXAt.Fl.EI BLU/ R , BLUE WITH RED TRACER

1 ijK

BRAKE LIGHT ~8:l SWITCH

Y

AUXIL I ARY SHUT- OFF SW I TCH & THROTTLE I

Si\FETY SW 1 TCH

HI La BEAM

TAIL LIGHT GEI 94

ekN I Y'R P I rLbr®

HIGH BEAM I NDICATOR

HEAD L IGHT

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REGUL ATOR

CHASSIS GNO

BRN~ Y/R

,-------BRN ------,,---------,

~HI GH

~

T~B W..-.RMERS

HMOW""'-'ERS DUM. HEAT

BRN

~, I BLK ~--------~ t~~

::~ "u~'" ~-fu L I GHT

r----------,----BRN~

Zt'c!tr


(TEMPI BLK/w

~ SPARK PLUGS

E NGINE GNO. BLK

""'" u""' TEMP/BATTERY WARNING LI GHTS

_;;;;m;;; m ::~ ____ : __ ~.~-T~:~'---~~ .

LOW OIL LEVEL

SENDER POLAR 15 TO FUJ I HARNESS 1 NTERCQNNECT I ON

V! Ell( FROM THE BACK OF THE POLAR I 5 PLUG

~------BRN------------~ " ~ ---- -- ----~O_L_"~ ~ ~ _ ~~~r-:E_S'::;_. ~

I

(~E~~~ I ~ I ___ C}i II BLK/I

FUJ I HARNESS

""/BLK + 1 , _____________________ , IGNITION

ill'V.,TTERY I KI LL SWITCH - - I I SWITCH

:Lfi~,~ : I I ( SPEED CONTROL r

R : ~51..IRI\NCE SW. f 2 1:

~ _ : W I : c- BLK 1!IAEN<E1t - , ____ ___ -- --R/Y-~BN ____ J BRN

OR~'tAR I 5 HARNESS ~ - R/BLU _ ... <1> - _L_ .?'- - -'

SELF SHUT OFF RELAY

l BLACKI

. - ~-U.J 1-HAR-NESS - - - - ~

9R/ GRN

R/BLU ~JV61.U-' ~ r=Y/O OR/BLK -' ~ GRN ~' eU( R/G ... , ----'>~----------!

AIR TEMP ,

BLK /w

ECU PIN ' 6. WIRE COLOR

1 P / BLU 3 W '\ BLU/ W 5 BLU/GRN 8 GRN/ R

COLOR CODE BLK BLACK BLU BLUE

=tf~rIFliM-~ 1 ~ ~ ::0: - r5:!~=--.~,~"~_. ~ "'_

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SCI MONITOR

U - z

10 BLK 1 I OR / BLK I'" Y/ BLU IS Y/GRN 16 GRN/Y i 7 BLK/Y

BRN BROWN GRY GRAY GRN GREEN PUR P URPLE LG LI GHT GREEN OR ORANGE P PINK Y YELLOW W WHITE R RED TWO COLOR W I RES ARE SHOWN WITH "A I N/TRACE COLORS EXAMPLE s BLU/R , BLUE WI TH RED TRACER

u u

lJ1 - z a: a « a: ---1 l-a u ---1 0.. W W

---1 :::l W LL

a I-U W I Z

OFf' ON HI

R:/g' IGNiTION SltITCH Y/GRN

BRN

BLK

R/W

R/BLU

OFF ON STAAT

1['5 . I~TlQo.I

~Ff£~n£

:1): R/Y R/W

YI • I SOLENO I 01

P IN ' 6. WIRE COLOR

101 : LG 102 LG/ BUo( 10 5 GRN/ W 106 R/GRN III BRN 112 BRN/R 113 P Ii" BRN/Y li S BRN/Y 116 R/eLK 121 BRN 122 BRN/R 123 BLK /R 12" BLK/ W 125 BRN/Y 126 R/ BLK

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(J

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THJMB WARMERS

REGlA...ATOR

STI\r OR

-:-CHI\SSIS GNO

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,RN

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IGNITION SWITCH


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BLX SW I TCH 6 TIflOTTLE

BLK

4 BRN) TAIL LIGHT GEI61

HIGH/LOW BEAM SW ITCH

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L __ __ __ ________________ ~

BRN/W

I "

SPARK PLUG

SPARK PLUG RECTIF IER

-:-ENGINE GNO

COLOR CODE BLK BLACK

OFf ON LOW HI GH BRN BROWN

::Ii =§ BLU BLUE B ..... TTERy

GRN GRN ENOINE GNO PUR PURPLE

IGNITION SWITCH OR ORANGE HIGH/LOW SWITQ-i R RED

W WHI TE Y YELLOW TWO COLOR WIRES ARE SHOWN WI TH MA IN/TRACE COLORS . EXAMPLE: BLU/R = BLUE WI TH RED TRACER

» BRN ~~)

'----R'"-----...,

STAATER RELAY CHASS IS GI'CJ

Er-Ki l f-E Gf'<I -:;:

Y/R

BAN

LOW BEAM LIGHT

HIGH 6EIJ.4 Il'Oi CATOfI

co CO C'f)

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w~ >0 0,

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HI ""

HANQWARMERS DUAL H::AT

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ENGI NE GND.

L-___ eRN ____________ --J

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IBLACKI

Ji27G~~/eLK J-LJ ff:~: 1:!!?=!/eLU~ eLK I R/G ? GRN/:-=1

STMTER R£LAY CHASSIS Gf'.()

ENGINE GNO -:;:-

COLOR CODE BLK BLI\CK BLU BLUE BRN BROWN GRY GRAY GRN GREEN PUR PURPLE LG LI GHT GREEN OR ORANGE P PINK Y YELLOW W WHITE R RED TWO COLOR W I RES ARE SHOWN WITH MA I N/TRACE COLORS EXAMPLE : BLU/R ~ BLUE WITH RED TRACER

" 1 R TEMP . SENSOR

WATER TEMP , SENSOR~

Y/GRN

L----------------~K-----~====~_,

ECU PIN ' 6. WIRE COLOR

, 3 . S e 10 II

" IS IB 17

P/BLU . 6LU/w BLU/GRN GRN/R eLK OR/elK Y/BLU Y/GRN G RN/Y BUVY

u

PIN ' & WIRE COLOR

101 = LG 102 LG/eu< 105 GAN/w 106 R/ GRN 11 \ BRN liZ BRN/R 11 3 P I I" BRN/Y 115 BRN/Y 116 R/BLK 121 BAN 122 BRN/R 123 6LK/R 12"" euvw 125 BRNIY 126 A/elK

u U1 -- z Z

0: 0 0

«: 0: -..J c- C-

O U ..J U

0.. W W W ..J ::l

--, W lL Z

"w« 1.10H'l'

R/G:~S,.IGNITION S' I T~ Y/ GRN

BAN

BLK

R/W

R/BLU

OFF ON ST,o,RT

KILL SW I TCH

BLKct::r:=J

BRN~ on ON

GRN~ y/:t±tj

HI/LOW SWI TCH

,

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OR

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LIGHT

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POLliA I 5 TO FUJ! YIIRNESS lNTERCONNECTIO~

v I EW F ROM THE 611CK OF I THE POLliA 15 PLUG

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STAT~

EN3INE GM) .

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M:CFSSORYl SWITCH REGtA.ATOR

Y

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Y~~ SP€:t:C'::K TEA

o

"1' I , I

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r-IGNITION

SYI' ITa-!

Y --· -n ---]:""~Y l ~ E LI GHT GEII S?

. • - ILlOiW( ORN". l.I ~ ... . q y I L_ - l .~> T, " . le>-. '- J '-r - -- --e0 . ! -

: I ,

ORN

BLK

SP..-..Af< FLUG

€NG'IUE BNO.

:§ HIClH LO,," SWITCt-4

r I

e''' -~-lF- - M , , , , , ,

- - - I~ .,." --tiLL

Y--tl "1EVEflSE w

L1rn-o'T

silT';" I ~ "".'ERSF. Ll o.-iT

CCLe)" eeoc BlK BLACK BRN BROWN BLU BLUE GRN GREEN PUR PURPLE OR ORANGE Y YELLOW W WHITE R RED TWO COLOR WIRES ARE SHOWN WITH MA IN/ TRACE COLORS. EXAMPLE, elU/R , BLUE W I T~ REO TRACER

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H I LO BEN.~

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BLK\A

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TH...IMBW..-.RMERS

REGLn...ATOR ACCESSORY

SWI TCH

CHASS I 5 GND.

BLlJ'.R

IGNITION 5wI rCH

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!? eRN

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BRN I B"~~ T ACHQME T EA

BRAKE LIGHT q tOR SWITCH

Y

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I BRN ~ ~ ~ I BRN ~,

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SAFETY sw ITCH

BAN/W

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OFF ON

::[f . I I.:)NI I I ON SWITCH

SPI\RK PLUG

SPARK PLUG

ENGINE GND.

G~~ y",C::=fj

HIGH LOW SWI TCH

u

COLOR CODE

BLK BLACK BLU BLUE BRN BROWN GRN GREEN OR ORANGE Y YELLOW W WHITE R REO PUR PUR TWO COLOR W I RES ARE SHO"N WITH MAI N/TRACE COLORS. EXAMPLE : BLU/R ' BLUE WI TH REO TRACER

BRN

REVERSE LIGHT

HEi\O L IGHT

HIGH BEAM IND ICATOR

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TAIL/ BRAKE LIGHT GEllS7

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U)

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!:i >< -a.. U)

!:i >< -!:i ><

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o

W/A

BL!VA

n o OIL

THJMBWI\RMERS

BL!VA OI!!J r i:LK\Wr" "~~,,~ ! r I AEDLENS I

BLK

BAN

1 ':'

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REGULATOR

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CHASSIS GND

SENO£A y

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LOW O I L LEVa =B .,~" 1"' U. ,~,~~

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BAN eRN I

IGNITION SWITCH

SRME LIGHT

BRAKE LIGHT ctE:- ~I'h. SWITCH

Y

--------, I

TACHOMETER

T .... IL LIGHT GEI61

L~ ______ BAN 11 BAN I: '=="""1

BAN

I BAN------,

BLK ~LK "UX IL IAAY SHJT OFf" sw I TCH 6. THROTTLE

SAFETY 5W I TCH

- -- -

SP"RK PLUGS ENGINE

GNO

::Ir ON

IGN ITION SWITCH

~ (

IGNITION COILS

=§ HJGHlLOW SWITD-t

COLOR CODE

BLK BL"CK BRN BROWN BLU BLUE GRN GREEN PUR PURPLE OR OR"NGE R RED W WH I TE Y YELLOW TWO COLOR WIRES "RE SHOWN WITH M"IN/TR"CE COLORS . EX"MPLE : BLU/R , BLUE WITH RED TR"CER

-eA~

t~ HEAD LIGHT

HIGH BEAM INDICATOR

C\J en C')

.q(J)

00

........ cx:>< 20:: a:: .... e O«s w'" .... 0) w.~ :>0 cO) o.~ m·~

3: ~ en en ,..

r-----------~-------------ORN------------~

OU</w

OLK OLK • • ""mLW

~

. 1 SPARK PLUGS

ENGINE GND

IGNIT ION CO I LS

REGULATOR

ENG I NE I<H--' GND

~

HEAD LIGHT

HI - LO SWI TCH

HANDWI\RMER SWITCH

W/ BLU

ORN

ACC. LIGHT

BRAKE LIGHT

HANOW ARMERS DUAL HEAT

TEMP . LIGHT

LOW OIL LEvEL

SENDER

TEMPERATURE SENDER

,-------------------------- -- ----------, I I i I

r---------------OLW~======~ ______ , ---------------------_1 EFI

RELAY I BROWN)

CIRCUIT BREAKER

: ~~ Il"L"C==: R/W ! ~I~ ~~II III ENGINE ~ - - - - ----- B~ - - - - - ~ ? ~ Y/8LK j 1

BLK

BRN

R

R/ W

GNO R/PVA~

L---~==---D=~:=O R/ Rn lr FUS [ BLE LINK

KILL SWITCH

~ OFF ""

BLK

BRN

R

R/W

KILL SWITCH

~ OFF ""

I GN I T I ON I GN I T I ON

CRANK CASE TEMP . SENSOR

R/I'" l___ AIR TE ~ .... ------:--"";'"

BRN BRN CHASS I 5 GNO gmSW ITCH MSW' TCH STARTER RELAY

BLK BLK R/W R/W ~lNE GNO 7

Y/BL Y/BL

OFF ON R/ PU

OFF ON START IRXL TOURING ONLY) -------- ---------- -- - ------- ------ -------_.

u u

U U1 Z Z

0: 0 0

<: 0: .J ~

~

0 U .J U

Q.. W W W .J :::J J W lL Z

u

BRN ') i

~ -- --- --- . ~~ y . ) 8LU/BLK I ~ REm00R -

~------~--------~ , , ,

LG/R LG/OU< . LG

IN .. H3

LG/ BLK L G/A

~- ----------- - --------------- - ~ I RXL TOURING ONLY)

COLOR CODE BLK BLIICK BLU BLUE BRN BROWN GRY GRIIY GRN GREEN PUR PURPLE LG LIGHT GREEN OR ORIINGE P PINK Y YELLOW W WHI TE R RED TWO COLOR WIRES liRE SHOW N WITH MIIIN/TRIICE COLORS EXIIMPLE: BLU/R ' BLUE WITH RED TRIICER

oo:;t 0 ) as

C0 (J)

C0

C') e .t: ::J

{:. ....I >< a::

....IE c:ce OC') -co a:: .-1-0 OC') We ....I .t: w·->3: o~ 00) m~

n

SPARK PLUGS ENGINE

GND

BRN

IGNiTION COILS

~====O=~:

BLK

BRN

R

R/W

K ILL SWITCH

~ OFF ON

IGN! TlON SWITCH

BRNm BLK

R/W

Y/BL OFF ON

, , , , , , , ,

, , , , ,

FUSIBL E

BLK

BRN

R

R/W

KILL SWITCH

m OFF ON

IGNITION SWITCH

BRN§; BLK

R/W

Y/BL

R/PU

OFF ON START

CRANK CASE TEMP. SENSOR

, AIR TEMP. SENSOR

~--------- -- ----

STARTER RELA '( CHASS!5 GND

ENGINE GNC ~

IRXL TOURING ONLY) -----------------------_.

~----------_r----

HANDWARMERS DUAL HEAT

TEMP . TEMPERA TURE LI GHT SENDER

OA rr~~

GRNOO

Y:RL±tj HI /LOW SWITCH

lf1

a: «: --.J o (L

z o a: fu W --.J W

--.J W :J LL

z o fU W ) Z

BRAKE LIGHT

T"IL LIGHT

OIL/BRAK E LIGHT

BRN~--L;:J

T----- y 0 y ""----t::.. ~ .--- -- ---" ~GUL~OR [LA 51 1

,-- ------ ----------I RXL

COLOR CODE BLK BLACK BLU BLUE BRN BROWN GRY GRAY GRN GREEN PUR PURPLE LG LIGHT GREEN OR ORANGE P PINK Y YELLOW W WHI TE R RED TWO COLOR WIRES ARE SHOWN WITH MAIN/TRACE COLORS EXAMPLE : BLU/R ' BLUE wiTH RED TRACER

..q-0)

C0

'<t 0)

00

..J(f) <t~ ()(f)

a:..... E ()'-w.s ..J (f) w >E Cm 0'-m~

C C') C 't: ;: ..:::t 0) 0) 'I""

6U< / R

GRN

u

STIITOR

6lJ(~ I I R

nueWARMERS

ACCESSORY SWITCH

REGlA....ATOR

rr' LOW OIL LEVEl..

SEmER

OIL LIGHT

Ta.t='ERA l1..R£ L I OHT IRED LENS I

r----8U< '=B

1" ff -'I'~~": ~'f~ ~ ,~ ~=rf)

8U<

-:-a-tASS I S !3f-IJ

IGN ITION SWITCH

BFW<E LI GHT

BRAKE LlI3HT@:---I'TvT\-SWITCH

Y

,---------------------

T Ao-o.£TER

8RN ---r-Th----..

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eRN

I BRN--------,

8U<

• eLK (

-:- -:- -:-

SPIIRK PLUGS ENGINE

GND

::11' a<

II3NITICJ.4 SWITo-t

u

-:-

IGNITION COILS

~~ YIRC==jj

HI GHILOW SW I TCH

COLOR CODE 8U< BLACI<

BAN :: BROWN

BLU = 6LUE GAN :: GREEN

Pl.fl : P\JPLE

OR : OAANGE. Y YELLOW W s WHITE

R • RED

TWO COLOR W I RES ARE SKlWN

WITH ""'IN/TRACE CCl..~. ElUI>A.E. 6l.U/R s eL.UE WITH RED TRACE

u

r AUXIL I I'IRY SHJT CFf' SWITCH & 'Tl-flOTILE

SAFETY SW I To-i

HI LO 8E"-"

el", 1 ~P l~

I-EI\O L IGHT

HIGH BEAM I~ICATOR

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n

ENG I NE GND

RN " R

BLK'R

n n

S I NGLE HEAT HANDWARMERS , Tf<JMBWARMER , ~BLU\R ------AND LOW OIL STANDARD ON LI TE GT . ~

THUMB WARMER

REGULATOR

ACCESSORY SWITCH

BLU'R

9.6 QH.4S

9.6 OHMS

n

LOW a I L LEVEL SENDER

ENGINE GND L-_ ___ BLU/R BRN =j 0 LAfG~'T

BAN/ W TO BLK/R TWIN 164 OHMS

Y TO BRN OR Y / R

GND TO BRN TO W I v ...,. ........ ..J

BRN

BRN E 3 BLK

IGNITI ON SWITCH

IGNITJON SWITCH

~eRN

BLK

BRAKE LIGHT SWITCH

RN

> I: r--r

AUXILIARY SHUT-OFF sw ITCH 6. THROTTLE

SAFETY SW ITCH

~ 9RN ------'-----,

I

~K

w

COl MODULE CU 6204

BRN/ W I

5T AALI TE. 6T

BLK (

SPARK PLUG

SP"RK PLUG

INDY LITE , GT ENGINE GNO

COLOR CODE

BlK BLACK BRN BROWN 6LU BLUE GRN GREEN PUR PURPLE OR ORANGE R REO W WHITE Y : YELLOW TWO COLOR W I RES ARE SHOWN wI TH MA I NITRACE COLORS . EXt\MPLEI BLU/A = BLUE WITH REO TRACER

OIL LI GHT

'=8

HI LO BEAM

TA I L LIGHT

GRN§OFF ON

BRN I· Y/: I "R ~.~"~

HEAD LIGHT

SPEEDOMETER IOPTION.\L

5TARLl TEl

co ~ C")

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>E c~ 00) r:c '" C

0) C

"i:

i Lt)

~ ,..

COLOR COOE

BLK BLACK BRN BROWN BLU BLUE GAN GREEN PUR PlR'LE OR ORANGE R REO W WHITE Y YELLOW TWO COLOR W I RES ARE SHOWN WITH Wli N/TRACE COLORS. EXAMPLE.

~ ~BLU'\R

THJt,46W ARMER

REGULATOR

ACCESSORY SWITCH

9.8 0I-t.IS

HNoOWARMERS SINGLE I-EA T .--. BAN

PU1

O IL LIGHT

~----- Y ------~·

BLU/R ' BLUE WITH REO TRACER 9.8 0I-t.IS

LOW ~EL .f----Y~ BAN 'l'-----1 --BAN~ -::- Y

~\b &?' Y I J I BLU/R BRN1)L~~ ~~ 1 .. j I Y-------j

CHASS I C; r,Nn .

5PEEOOIETER

STATOR RESISTANCES IGNITI ON SWITCH CJFr RLt-l START

ENG I NE GND. Y TO BRN OR Y/R I .3 TO .6 OHMS LI Io4IB I BLK t.4

BRN/w TO BU</R I 18~ 0I-t.IS (50 BRN ~ G

GNO TO BAN TO wi 0 0HI04S _I _I R B ~~ ~~

u

BRN

BLK'-R Y'-R

R/W S BRAKE LIGHT SWITCH WIRE COLOR

G TERM I NAL BROWN - GROUNO B TERM I NAL - REO - BATTERY t.4 TERMINAL - BLACK - IGNITION S TERM I NAL - REO/WH ITE - STARTER

IGNITION SWITCH

AUXI L IARY stfJT OFF SW I TCH 4. nflOTTLE

SAFETY SWITCH

TA IL L IGHT

:§ ~ BAN C HI/LOW SWITCH

W BRN/ W

SPARK PLUG

I NOY LI TE DELUXE

u

BLK C ECCE

SPARK PLUG Y

-::-ENGINE aNJ.

BATTERY -::-

ENGINE aNJ.

R

u

'----R' W-------,

R

STARTER RELAY CHASS I S aNJ.

ENS I IE (3N).

HI LO BEAt.4

BAN IY'-R

IT~ HEAD LIGHT

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00

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"'" (1) Q. :::J

(/) -~ o Q.

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w

n

SPORT SUPER SPORT SPORT TOURING

STATOR

l'1-UeW~ IcrTlOfrW... C»I tiP'MT 1'DI..MthWi

REGLLATOR

-= CHI\SS I S 6NO

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r------------eRN

ACCESSORY SWITCH

- ---==p;:;~ = ,i~ ~ ... -I ' '~ fW.IJW~ eRNl Y ~ S INGLE fEA

"0''''' ' •.• _ ::

BlW<E rfl----------l TAQiOMETER LI!3HT

I ( Y ') ') I

BRN/W

BAN/w TO BLK/ R 1164 0HdS

Y TO Y/R 1.2-.S 0HdS

Y/R, BRN, W, GNOO 0HdS

BLKVl

::liF

~ IGNITI~ SWITCH

IGNITI~ SWITCH

'----1 - eRN i ~ BAN !~: 'r=l''''1

BAN

, BAN --------,

BLK (

,---------------Ci SPIIRK PLUG

-= ENGINE

GNO

BLK

COLOR COOE

BLK BLACK

BAN BROWN

BLU BLUE

I3RN GREEN OR 0RAN6E

PUR P\JRPI...E

R REO

W WHITE

Y GREEN

TWO COLOR WIRES ARE SHOWN WITH WlIN/TRACE COLORS

EXJ\IFLE.

AUXILIARY SHJT OFF SWI TCH & ~TTLE

SAFETY SW I TCH

BLU/R ' BLUE WITH REO TRACER

TAIL LI!3HT

L-------'')B')OR -dl®

HI LO BEAM

TAI L LII3HT

~§ HI/LOW SWITCH

HIGH BEAM I~ICATOR

HEAD LI!3HT

co (j)

C")

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00

w co co

~ CD .j:>.

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PIN /I & WIRE COLOR

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-=- y I ~:v~i '-------- BRN ~---~.!~-~-= - -- -- ~ ::: 1

I I

: TAC1QEfER :

~ -~!:~~~~:!: - ~ "'%11*1, ~lL- I ~ ! __ L-_____________ Y ? I

r I

W BRN/ W

ENG I NE GNIJ .

e~K'-R

BRN

I

I

I ::Ir ON

IGNITION SWITCH BRAKE L IGHT q tOR

SWITCH Y

I _n. IGNITION ""\U'TD-I

I _ 11 ~ -i(i I~' eLK

~UX l LIAAY SHIT OFF SWITCH & llRlTTLE

SAFETY SW ITCH =~ HIGH LOW SWITCH

~--------~------------------ ~ \ ~ HI LO BEAM

SPARK PLUG

------- - -----------BLK COLOR CODE rt

BLK BLACK ~--------------------------------------r--------~ BLU BLUE Y~

SPARK PLUG

-:

BRN BROWN GRN GREEN OR ORANGE ~ W

~ ~~T~~W SWITCH ~ BAN

R REO I PUR PUR REVERSE LI GHT TWO COLOR WIRES ARE SHOWN WITH MAIN/ TRACE COLORS. EXAMPLE. BLU/R = BLUE WITH REO TRACER -

HIGH BEAM

I I "'" j- 1~I1ll

TtLtis-

..... <0 <0 01

~ ::l. :::l

cc C I:»

CCOl "'0 I:»c 3-(

I

:E~ _. m g.o -t-l "':D 1:»_ "0 .» ><.

tn. CI) ~ CI)

~ >< -CI) ~ CI)

~ >< -n. CI)

~ >< -~ ><

..JE <Cf:! OC) - ('0 a: 0-t-C OC) We ..J 0t: WO->3: ell) 00') m~

XLT XCR 600 I CW~

5l..K/R ,

w

R W/ R

ACCESSORY SWITCH

rr' LOW OIL LEVEL

5eIlER

OIL L l tIHT

l'EM'£RI\ TUlE L I ClIfT

REGtA..A TOR '=€)

.~~: 1: j l~~ -::-

CHASSIS GNO

L-------_________ y

BLK

WIRES RES I STANCE

BLK/ R TO R 4.6 Of-t.cs

W TO W/R 100 0HI0IS

COIL PRIw.RY .4 Of-t.cs SECONDARY 4.000 0H0<S

l~r:eB:ULKK=;=~OR~=;~r:;;""~=r~OlJ(;;:;'-l--;::,:-;"'~=r~OlJ(;:;;;-1 l

BRN

1 -::- -::-

SPARK PLUGS ENGINE

GND

-::-

BRAKE LIGHT

I c' Y ) ) I

IGN ITION BRN COILS

:II' 0<

IGNITION SWITCH

IGNITION SWITCH

BLK I\UX I LI ARY SHIT OFF SW I TCH <I. nRlTTLE

SAFETY SW I TCH

~C C BLK ( ( COLOR COIlE

BLK BLACK BRN BROWN BLU BLUE GRN GREEN PUR PURPLE OR ORANGE R RED W WHITE Y YELLOW TWO COLOR WIRES ARE SHOWN WITH MAIN/ TRACE COLORS. EXAMPLE. BLU/ R = BLUE WI TH RED TRACER

,.--------------.,

BRN

I D TETf£R SW I TCH

• ___ ~_X~ _~Y ___ •

TAOOETER

TAIL LIGHT

~§ HIClH/LOW SWITCH

f£IID L I <lHT

HI<lH BEAM II'() I CATOR

o ....-C')

~

~

...JC) <l: ,!: (,,) ... - :::J

I=~ frl~ ...J)( WI

> E ero 0'" CD~

C C) C 'i:

~ Lt) 0') 0') .....

( .-...../

r-----------~ -----------,-----------,

STATOR RESI STANCES 1:1: 10:1.1 . 6UUR-R

W-W/R

COILt PRIMARY SECONOflRY

.... 6 ot-t.tS

100 QH.IS

• • QH.IS .000 OH.<S

eLK OA ___ =t-_ ..

rBlJ(

I SPARK PLUGS

ENG INE GNn

7

a-tASS 15 GND

"""

7

BAN ....

OFF LOW HIGH

YeL:IR~ BLUL=tiTI H.o\J'.VWI\At.ER SWITCH

Em IGf\lITlON SWlTa-I

LOW OIL LIaHT

Ta.'.

LOW 0 I L LEVEL SE>IJER

HN"'OWI\RMER RES f*O.31 BRN-BLU/R B . B CIHrAS BRN-BLU 19.2 QH.IS

r------ -- --- -- ------

..... UXIL I AAY SHJT OFF SW I Ta-t & TIflOTlLE

SAFETY SW I TCH

,< < eLK ) )) )) I I I . L ____ _ _________ ___ _____ ~

COLOR CODE BLK BLAD< BAN BROWN BLU BLUE GRN GRN "'" PrnPLE OR """""*' R REO W WHiTE Y = YELLOW TWa COLOR W I RES ARE SH'JWN WITH MA I NITRACE CCl..ORS. EJW.f'LE ' BLU/R : BLUE WI TH RED TRACER

Et-GII'E Gf'.V

\.J

~------------------~

'-------R'"-----....

STARTER REl.A Y CHASS 1 5 eN)

ENG ItE C3r'1)-===-

'=8 ~~

f1JEL SENOEA PUVW- BRN aPTY 0 CH.tS fU.L 90 QH.IS

5F'EEIXlOETER

T ACK)t.ETEA

PLWW

L-______ ~ 'l 'l=' ,

Y ~ -')

~0~fLRSII r

l----l----+.-h.:::.:..BRN~

YIR

BAN

r" IL LIGHT

+l"""~ BRN<E LI GHT

~~ TAl l LIGHT

LOW B£.N,t LIGHT

:§ HJGt-VLOW SW I TCH

HIGH SEN.! 1r-.c I CATOR

~

~

~

T""" T""" T"""

C0

..J >< [I:

..JE «~ (0) -nl [I: .-I-C (0) We ..J 'i: W,-

>3: CLl) 00) al~

STATOR RESISTANCES BLK/R-GRN 288 OHMS R-GRN 20 OHMS W-W/R 96 OHMS Y-BRN . 2- .4 OHMS GRY-GRY/ W .4'.8 OHMS BRN/ W-GRY/ W .3·.S OHMS

r-----------~L-------------B~------------__1

-:

~ BLK BRN R

SPARK PLUGS KILL SW ITCH

IGNiTiON COILS

BRN BLK R/ w

Y/BL

REGULATOR

~

HEAD LIGHT

GN

HI-LO SWITCH

HANDWARMER SW ITCH

W/BLU

TAIL LIGHT

BRN

ACG. LIGHT

BRAKE LIGHT

HANDWARMER RESISTANCES BLU/ R-BRN 9.8 OHMS BLU-BRN 19.6 OHMS

TACHOMETER

TEMP. LIGHT

LOW OIL LEVEL

SENDER

TEMPERATURE SENDER

OIL/ BRAKE LIGHT

~;~+--------- -- -~;;N-O~~~-~~: FLEL 5eI)EA RXL TOUR I NG I PLR/W·BRN EMPTY 0 ClHotS FULL 90 QH.tS m R/ W

R/PU ----------------B~----------------,

~F EFI RELAY

(BROWNI

it I ~L" I R/ ' : ~ILeL~~r RE~J~E ~--- - R::· r BR r YI BLK

FUSIBLE LINK I CJ= BRN=(] RIY

L;~R3;RlW

STARTER RELJ". Y CH .... SSIS GND

ENG I NE GND -::;

STANDARD ON RXL TOURI NG

CASE TEMP. SENSOR

A I R TEMP . SENSOR

, ~:rm]j/::'\i' o y I

I r.== BLUIY BLUIBLK 'lmmm __ ~~~_'~~~I __ L __ .

LG/eLK LG/R

~I' ~~~R ~=:~~ ~'I ~Il:= L~G~ > La

COLOR CODE BLK Bl...A.CK BLU BLUE BRN BROWN GAY GRAY GRN GREEN PUR PURPLE LG LIGHT GREEN OR ORANGE P P lt-.I< Y YELLOW 'If WHI TE R : REO TWO COLOR w t RES AAE SH'JWN wI TH MAl N/TRf,CE COLORS EXNM'LEI BLU/R : BLUE WITH RED TR.A.CEA

N T"" T""

C'?

-.::t 0)

00

U)

..... ..... U)

~ ~

r

ST A TOR RES I STANCES

~~~~~-GRN 1288 OHMS

W-W/R Y-BRN GRY-GRY/ W BRN/ W-GRY/W

,------------L------------BRN----____ _

z :5

SPARK PLUGS

KILL SWITCH

BLK

BRN

R

R/ W

IGNITION COILS

CO I L RES I STANCES

BRN

BLK

R/ W

Y/BL

R/PU ~ r _ __ P~ ___ o~_ OFF

REGULATOR

HASSI S GNDI

~

HEAD L IGHT

H I-LO SWITCH

GR; I i I I Y/R T

HANDWI\RMEA SWITCH

BAN

ACC. LIGHT

n

HANDWARMER RESISTANCES BLU/R-BRN 9 . B OHMS BLU-BRN 19.6 OHMS

TEMP . LI GHT

TEMPERATURE SENDER

()

~0A------~4-~~----~----~~----

OA

TAIL LIGHT

LOW OI L LEVEL • __________ ~~P~B __________________ ___ ,

I BRN I i

FUEL SENDER PlR/W- 8RN EMPTY 0 CH.4S FU...L 90 OHMS

5T "NOARD ON : RXL TOUR I NG ,

r---------------B~----------------,

EFI REL AY

IBROWNI BRN ~ ~. y 0 y ') I

I ~ SLUt ". BLU~~ 1___ Il ___________ ~~~;; ___ _________ ~ i~ I Cell" R/w ; ~I~~~ ________ __ _ ~N _ ~ ~ B ) Y/BLK

COL OR CODE BlK BLACK

STARTER RELAY CH"SSIS GND

ENGINE GND -=:;

, , , , , , , . ___ :"':. ":".?~~~ _ ~~ _R_X':-_ ~~~~ I-"_G __ !

CASE TEMP . SENSOR

A I R TEMP. SENSOR BLK

INJ ' 3

LG LG/BLK

LG/R

~·~R =~ 'I - L~~ > -=:=- LG

BLU BLUE BRN BROWN GRY GRAY GRN GREEN PUR """"'-E LG LIGHT GREEN OA ORANGE P PINK Y YELLOW W WHITE R = RED TWO COLOR W I RES ARE SHOWN WITH MA I N/TRACE COLORS EXNo/PLE I BLU/R = BLUE WITH REO TRACER

...A.

<0 <0 UI

~ ~, ::l

(Q

C 5)'

(Q

Ql 3

OJ o c -<

'm :Or ><m ro o-~ c-.0 _. » tSr

.... Il. -en ~ en -E ... o -en

....IE ~ CIl) Om m~

,--------Y-------, r-------.-BRN ------------------~------------------~ OIL LleHT

5TORM/SKS rr' W

W/R BLK/ R

If" BLK

STATOR

'---'---- BAN

STATOR RESISTANCES BLK/R-GRN 2 48 OHMS GRN-R 20 OHMS W- W/R 96 OHMS Y-BRN . 2-.4 OHMS

ACCESSORY SWITCH

REGULATOR

-::-

LOW OIL LEVEL sevER

TEl<PERA TLfIE L leHT IRED LeNS I

'=B .~~: 1:.1 ~~~

BRAKE L IGHT

TACHOMETER

SECONDARY COIL RESISTANCE PRIMARY 0.4 OHMS ±ISX

SECONDARY 7500 OHMS ±20X PLUG GAP 3700-6300 OHMS

I ( Y ) ) I

R

BUVR BLK

GRN

w

1m ORBLK 1

-::- -::- -::-


BAN BROWN

BLU BLUE GRN GREEN

P~'~E

OR ~ Y YELLOW W WHITE

R REO

TWO COLOR WIRES I\RE SHOWN

WITH MIIIN/TRACE COLORS . EXAMPLE . BLU/ R = BLUE WITH REO TRACE

-::-

IGNI TION COILS

ENGINE GND

::Ir ON

IGNITI ON SWITCH

IGNITION SWITCH

BAN

\ BRAKE LIGHT ctEOROR~--

SWITCH Y

r

----_ ... _,

I\UXILIARY SH.IT OFF SW I TCH <!. ~OTTLE

SAFETY SWITCH

L ______________________ ~

TAIL LIGHT

~§ HIGH/LOW SWITCH

H I La BEAM

~ ~

~

C")

'<:t (j)

00

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