{"id":39339,"date":"2020-05-07T20:46:38","date_gmt":"2020-05-07T11:46:38","guid":{"rendered":"https:\/\/www.decoboco.info\/en\/?p=39339"},"modified":"2026-09-24T13:45:23","modified_gmt":"2026-09-24T04:45:23","slug":"z1r-1-main-harness-replacement-mosfet-regulator-handlebar-lock-2","status":"publish","type":"post","link":"https:\/\/www.decoboco.info\/en\/20200507\/everyday-events\/z1r-1-main-harness-replacement-mosfet-regulator-handlebar-lock-2","title":{"rendered":"Z1R-1 Main harness replacement, MOSFET regulator, handlebar lock angle, key replacement and more"},"content":{"rendered":"
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Replacing the main harness on a Suzuki GSX-R or oil-cooled bike is a completely different level of work.

With OEM parts, it’s just a matter of removing and reinstalling, but with a repro harness\u2014especially an adapted one\u2014you start wondering, “Huh??? What’s this? Why isn’t it being used?” and so on.

Once you start noticing these things, you can’t move forward until you understand what they’re for.

I’ve mostly figured it all out and made a manual, so it should be smooth sailing next time. <\/p>\n\n\n\n\n\n\n\n

\"\"<\/figure>\n\n\n\n

The repro harness uses wedge bulbs, so we’ll swap them out for LEDs.

AUXITO T10 LED White<\/a>

These are pretty good\u2014we keep them in stock regularly. <\/p>\n\n\n\n

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A solid insertion point gives you peace of mind. Wires bent and sticking out can cause contact issues, so be careful. <\/p>\n\n\n\n

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The meter that was dimly lit before should now have much better visibility.
Always check that it lights up before assembly. <\/p>\n\n\n\n

\"\"<\/figure>\n\n\n\n

This gives it a nice crisp feel. <\/p>\n\n\n\n

\"\"<\/figure>\n\n\n\n

When converting models with a single turn signal indicator to LED, you need to be careful.

I use a diode to rectify the left and right signals.

(Hmm, not making sense?)

First, models with a single indicator work with

left turn signal positive and right turn signal positive.
\u2193
When you swap these to LEDs, only one side will light up because LEDs only conduct current in one direction.
\u2193
You run both left and right turn signals into a diode and pull out a single wire.
*Occasionally even after rectifying, some current leaks through and creates a dim glow, so watch out.
\u2193
The dual indicator wiring is completed with one wire from the diode and ground. <\/p>\n\n\n\n

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\"\"<\/figure>\n<\/div>\n<\/div>\n\n\n\n

Here’s a handy side stand diode\u2014Suzuki 36611-38A00<\/p>\n\n\n\n

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And I found this today… I’m pretty sure this is it… no, definitely this.
Sumitomo Electric 090-type MT series 3-pole F connector (with terminals) \/ 3P090K-MT-F<\/a>
<\/p>\n\n\n\n

\"\"<\/figure>\n\n\n\n

This time I adapted a PMC Z1000MK II harness for the Z1R.

Two mystery connectors came with it, and the instructions said to connect them first.

Looking at the wiring, I thought, “Hmm??? Why plug this in? If this conducts, the light won’t turn off, will it?”

Then I looked carefully at the manual and… there it was: “for constant illumination.”


Repro harnesses run deep… the lesson is to read the instructions properly.


Working on the Z1R today, I realized something.

If you can use one, going with a headlight case would let you route the wiring much more neatly… if it fits, that is.

*The Z1R is basically just a lens, more or less.

<\/p>\n\n\n\n

\u3010Progress\u3011
\u25cf Old harness removal
\u25cf Other electrical components removal
\u25cf Left and right handlebar stopper welding (lock angle correction)
\u25cf Watanabe coil bracket cutting, spark plug wire securing
\u25cf Tail light and rear turn signal wiring routing
\u25cf Electrical plate in progress
\u25cf Handlebar hole drilling, left and right switch installation
\u25cf MOSFET regulator wiring
\u25cf Starter lead wire modification
\u25cf N switch\/OP switch wiring
\u25cf Honda fuse electrical installation
\u25cf IC turn signal relay electrical installation
\u25cf Starter relay connection 5\/6
\u25cf Fuse wiring 3 systems layout only 5\/6
\u25cf Mystery wiring confirmation 5\/6
\u25cf Harness marking 5\/6
\u25cf All main harness layout, engine start and voltage checks, operation verification 5\/7
\u25cf Meter indicator lamp LED conversion 5\/7
\u25cf Turn signal indicator rectification 5\/7<\/p>\n\n\n\n

<\/p>\n","protected":false},"excerpt":{"rendered":"

Replacing the main harness on a Suzuki GSX-R or oil-cooled bike is a completely different level of work. With OEM parts, it’s just a matter of removing and reinstalling, but with a repro harness\u2014especially an adapted one\u2014you start wondering, “Huh??? What’s this? Why isn’t it being used?” and so on. Once you start noticing these things, you can’t move forward until you understand what they’re for. I’ve mostly figured it all out and made a manual, so it should be smooth sailing next time.<\/p>\n","protected":false},"author":2,"featured_media":39328,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"pochipp_cv_data":"","swell_btn_cv_data":"","footnotes":""},"categories":[1924],"tags":[162,169,77,115,205],"class_list":["post-39339","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-everyday-events","tag-electric","tag-main-harness-replacement","tag-uotani","tag-z-aircooled","tag-z1r"],"_links":{"self":[{"href":"https:\/\/www.decoboco.info\/en\/wp-json\/wp\/v2\/posts\/39339","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/www.decoboco.info\/en\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/www.decoboco.info\/en\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/www.decoboco.info\/en\/wp-json\/wp\/v2\/users\/2"}],"replies":[{"embeddable":true,"href":"https:\/\/www.decoboco.info\/en\/wp-json\/wp\/v2\/comments?post=39339"}],"version-history":[{"count":0,"href":"https:\/\/www.decoboco.info\/en\/wp-json\/wp\/v2\/posts\/39339\/revisions"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/www.decoboco.info\/en\/wp-json\/wp\/v2\/media\/39328"}],"wp:attachment":[{"href":"https:\/\/www.decoboco.info\/en\/wp-json\/wp\/v2\/media?parent=39339"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/www.decoboco.info\/en\/wp-json\/wp\/v2\/categories?post=39339"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/www.decoboco.info\/en\/wp-json\/wp\/v2\/tags?post=39339"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}