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Sunday, February 13, 2011

Wire a Harley or Thunder switch on a Vulcan correctly

This is the original wiring guide for the Thunder Mfg switch which is basically a HD softail switch (there even a how to do it on the cheap.)


DO NOT WIRE YOUR SWITCH THIS WAY!

Here's why.

This is how the stock switch works. Tail1 and Tail2 connect to each other in the ON position not the directly to the Battery(12V+ White Fuse at 30Amp).



Then a plug switches the Blue to Red/Blue and it goes to the fusebox. The Red goes straight the taillight bulb.

The Red/Blue(Blue) wire should be fused(10Amp) and feed the taillight.






So if you wire it like the original Thunder diagram, then white wire will feed the red tail light without the 10Amp fuse for it. Yes, the stock park position works that way, but you're not bouncing down the road in that position.

So if you use a switch a Harley/Thunder switch, then just permanently connect the Red/Blue(Blue) to the Red. The taillight will work fine. You won't have a park position, but you will have a taillight fuse.


Also that resistor on the Gray wire is very important, too.

100 ohm Radio Shack P/N 271-1108 (Card of five).

6 comments:

  1. why is the resistor needed? its not on the original so why when putting in the harley switch why do we need one? thanks for the info ive ordered my switch will be doing the job this weekend.

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    1. It's not shown on any Kawasaki wiring diagrams, but it's in the switch. Break one open and you'll see it. The lower voltage from the resistor to ignition box is an anti-theft measure. If you try a quick hot wire it won't work.

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    2. ok that makes sense now.. thanks man it looks great i love it!!

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  2. Great article, and I needed that resistor

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  3. I would like the park light, can I put a 10a fuse in the tail light cable???

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  4. Help! So red and blue together on one end brown and grey on the other end and white in the middle? I replaced the resistor and still nothing. Please help.

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