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Discussion Starter #1
I'm trying to install a new ignition switch into my bike as I've used up the spot for the old one. I have three different wiring diagrams and non of them have a blue/black tr or brown/blue tr. I'm really hoping someone could help me out with this.





2006 TW200 Bobber build.
 

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Stock Wires for Main Switch: [I am looking at the wiring diagram as I type this.]
Black = Earth (this description does not explain all 'earth' situations. But for our purposes, it will do. Earth is like ground, however it is not a direct path to the ground on the bike, or the negative terminal on the battery. On our bikes it feeds the "start" switch, and the common wire for the front flashers on the turn signal)
Black/White = goes to the CDI. When this switches to earth(ground), the CDI turns off.
Red = goes to battery via fuse
Brown = When the switch is ON, this wire sends power to the bike so it will operate.

I am looking at the wiring diagram. In the off position, the stock switch has Black/White switched to Black. When it is on, this connection opens.

The other part of the switch, when off, is open. When on, it switches Brown to Red[on the switch]. This Red wire goes to a connecter, and then becomes a Red/White wire. This goes to the battery with a fuse in line. The brown wire of this pair [side of the switch] supplies the positive voltage for things like lights, horn, other stuff that needs electricity.

So think of the two halves as two independant of each other, with their toggles tied so they move at the same time.
 

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Discussion Starter #4
Hahaha. I wish I could say I understood that. When you turn the key the ignition makes two connections simultaneously? In my case blue/yellow to blue/black and red to brown/blue. Is that right?


2006 TW200 Bobber build.
 

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The two-switch part... One part goes from closed [circuit on] to open [circuit off]. This is the one with the Black/White & Blue wires.

At the same time, the other part goes from open to closed [again, circuit on]. This is the one for the Brown & Red [becomes Red with White after the connector] Wires.

These are the colors from the stock switch.

[More to come -- I'll help you match up the colors in the next post or two]
 

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I went back up, and edited a post. I made an error. So, start with what I posted above, then come back here.

Read this whole post. I have a few questions for you at the end. Don't wire anything until I confirm details based on your answers. I want to be as sure of this as you do. I'm aiming for success and accuracy.

On our bikes, the Red / White wire from the original main switch goes to battery. This is where you'll hook your Red wire, based on what you said in post #2.

It looks like the Red / Gray wire connects to the bikes Brown wire. This wire [on the bike] goes to several lights, horn, and the Ignition Circuit Cut-off Relay.

Your Red / Black wire. My best guess is that this goes to the Black wire on the bike.

And here's where I'm confused. What about the original bike's Black / White wire, on the main switch?


What year is your TW200?

Do you have an ohm meter to test some switch positions and continuity? I can help be more accurate with those readings.

Your pictures from post #1, and the descriptions in post #2... Post 1 shows 4 wires. Post 2 lists three wires. And they don't match. Tell me what I'm looking at in the pictures. New switch? Old switch / Bike Wiring?

I'm confident on my ability to help, but I need more information to be completely accurate.
 

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Discussion Starter #7
Ya sorry, my original post didn't do a good job of labelling my pics.

This is the inside of my original ignition. It's a 2006.

This is a pic of the DS ignition with the original in the background. So yes the original has 4 wires and the new one only has 3. I don't have an ohm metre, but if it's not too pricey I could get one.


2006 TW200 Bobber build.
 

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I am using a Yamaha [factory] Service manual that covers 2001 - 2013. I bought it last year.

I was trained as an electronics technician in the U.S.N. I understand wiring like our bikes. So the fun... Let's Only focus on the original bike switch and wiring for this post. Just this one. I'll cover the new switch in my next one.

When turned Off, our bike's Black wire is switched on [circuit closed] so it electrically connects to the bikes Black / White wire. The Black / White wire goes to the CDI unit. This part of the switch in effect, grounds the CDI and front flasher. In this case, I'm concerned about the grounding of the CDI.

When we turn our bike on, the Black wire is switched off [open circuit], so it no longer grounds the CDI, and front flasher.


Okay, now for the color differences: Again, still with the original switch. What are the colors of the wires, that the stock switch connected to, on the bike? I.E. Ignore the colors I see on the switch you posted. Tell me about the other end of the plug they connected to. [I hope it matches up with the wiring diagram]
 

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Discussion Starter #11
When I took the back off the DS ignition it snapped off the holding tab. Now it won't stay in there. Sigh.
Now that I've ruined that, we can continue as if I haven't, in case someone else want to do this or we can call it a day on this one. I can't really afford another $45 to replace this one.


2006 TW200 Bobber build.
 

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I'm here to help, and I'm calling you the boss on this one.

I've had that kind of thing happen too. Some epoxy or similar adhesive sometimes can fix it.

I will say, that if you do get another switch, look for one that WILL work with the TW. I.E. Has 4 wires, and is meant to work with our bike.

I was scratching my head about the 3-to-4 wire connections and finding a "way" to make it operate properly. Again, I'll do what you ask.
 

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Discussion Starter #13

Not the best pic, but ya after the plug I still have the same wire colours. The only wire of the 4 that makes it's way all the way to the CDI is the blue/yellow.

Unless something changes inside the harness.


2006 TW200 Bobber build.
 

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Discussion Starter #15
Ya, I think this "universal" custom switch is only universal for Harley's. Let's bail on this one, I'll have a ton of questions for you Dubzha so I'm glad your qualified.

I still got to sort all this out. Haha.


2006 TW200 Bobber build.
 

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I sit in awe of people who understand electronics. My entire understanding can be summed up in the statement, "don't touch the third rail".
Croatoan, To me, you are spot on. I don't mess with stuff I don't know about, and the third rail is always a No-No, without a lockout.
 

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Not the best pic, but ya after the plug I still have the same wire colours. The only wire of the 4 that makes it's way all the way to the CDI is the blue/yellow.

Unless something changes inside the harness.


2006 TW200 Bobber build.
They have changed the wire colors. I am not surprised. Your Blue / Yellow is the one in the diagram that is Black / White.

Keep the orginal switch intact, and on hand. We'll use it to double check any replacement switch.

Regarding an ohm meter. You can pick up a meter, multitester, what-cha-ma-callit at places like Harbor Frieght, Northern Tool, local auto parts store. Mine cost $4.99. Here's my rule -- make sure the battery inside the meter costs less than the meter. If it does't, buy a boatload of them, take the batteries out, sell them on ebay -- use the money to buy a different meter. Okay, got carried away. I like the meters that use a 9volt battery. That's close enough for what you need.

The only other rule is, Do Not Try To Measure OHMs [resistance / continuity] on ANY wire or circuit that has electricity flowing. If you do, you will let the magic smoke out. Then it's time to buy another $4.99 meter.

You don't need to buy a meter, mind you. I'm just letting you know that for most stuff people need a meter for, these cheap ones are close enough. No need to spend more.

I have a really nice [expensive] one when I need to be really accurate. Most homeowners do not need this. I have it because of the work I do. It's a 1978 vintage. Paid a lot for it, worth every penny to me.
 

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Discussion Starter #19
Sweet. Thanks Dubzha. I'm kinda the opposite. I'm always like "that guy did that, I can too". Then I get in way over my head and I spend the evening in my garage calling myself names.


2006 TW200 Bobber build.
 

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My Dad told me lifes too short to figure out everything all by yourself. That's what friends are for. Don't call yourself too many names. :cool:
 
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