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Replacing standard ignition switch Replacing standard ignition switch
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Yamaha Tech Originally the Yamaha XT600 Tech Forum, due to demand it now includes all Yamaha's technical / mechanical / repair / preparation questions.
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  #1  
Old 12 Feb 2017
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Replacing standard ignition switch
Hi,

I’m hoping for some electrical advice on my 1997 XT600. I’m doing some customising of the front end and as part of this want to replace the ignition switch with a simple key switch that would control continuity between the red wire coming from the battery and the brown one that takes the power on to the bike’s circuits.

The standard ignition switch also establishes continuity on two other separate circuits - one controlling the parking lights and some instrument lights, and another which connects the CDI with the clutch, sidestand and neutral switches. My plan is to make these circuits permanently continuous. I’ve studied the circuit diagram and can’t see any reason not to do this but am well aware that I could be missing something obvious. Does anyone know if I’m asking for a whole lot of problems by doing this? Thanks in advance for your help.
Last edited by connal; 12 Feb 2017 at 11:07. Reason: To subscribe to the thread
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Old 13 Feb 2017
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I'd think you may get a drained battery if not shutting most of those things off when the bike is just sitting ,Otherwise it makes no difference if they're on with the key or just always on.
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Old 13 Feb 2017
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Quote:
Originally Posted by connal View Post
I’m hoping for some electrical advice on my 1997 XT600. I’m doing some customising of the front end and as part of this want to replace the ignition switch with a simple key switch that would control continuity between the red wire coming from the battery and the brown one that takes the power on to the bike’s circuits.
This simply turns on/off the bikes lights/horn.

Quote:
Originally Posted by connal View Post
The standard ignition switch also establishes continuity on two other separate circuits - one controlling the parking lights and some instrument lights, and another which connects the CDI with the clutch, sidestand and neutral switches.
Think you might find the CDI circuit turns the engine off. If you don't replicate it the bike may keep running.. not good for theft prevention. I'd suggest you test this first, before you buy the parts.
Of course it may simply stop some one hot wiring the bike by simply jumping from the battery to the CDI. Again this is a theft prevention measure.
Last edited by Warin; 13 Feb 2017 at 22:40. Reason: Add alternatve reason for CDI wiring
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Old 14 Feb 2017
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Thanks for the replies guys. I had been approaching this with the view that Yamaha must have a good reason to makes those two circuits switchable at the ignition switch but your idea Warin makes sense. It could just be a way of making it harder to hot wire the bike. The kill switch is on the same CDI circuit so I should still be able to turn the engine off. I think I'll go for it anyway and join the wires temporarily to see if it drains the battery.
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Old 14 Feb 2017
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IIRC the kill switch grounds out the cdi thus killing the engine . I'm not 100% sure on that or if I'm thinking of some of my other bikes as that's how they are. If that would be the case , leaving the cdi hot always and the kill switch on would cause a constant short.
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Old 14 Feb 2017
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That sounds worrying. To my untrained eye the circuit diagram for my bike seems to show that there would be no power going to the CDI if the connection between the red and brown is broken at the ignition switch. If you have a moment to look at it I would really appreciate you letting me know if I have got this wrong. http://www.horizonsunlimited.com/hub...diagram-1-.pdf
Last edited by connal; 14 Feb 2017 at 16:37. Reason: To insert link to image
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Old 15 Feb 2017
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Ya, it'll be fine . The kill button just cuts continuity , not ground it out.
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Old 15 Feb 2017
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For theft prevention .. just fit a small switch somewhere hidden that does the same as the original key switch for the CDI box ... don't forget it when the bike refuses to start!
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Old 15 Feb 2017
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Thanks for the advice and ideas. I'm off to find a fiendishly clever place to hide my switch.
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