OEM harness Headlight connector - 08 550E

canadius · Apr 16, 2018

Hello,

My wiring harness, over the course of the various previous owners’ mods, is a patchwork of aftermarket connectors and additions.

So as part of my ground-up restoration, I’ve ordered a new one. I’ve ordered the full dual-sport harness – 800.11.075.500. It’s back-ordered, and in the meanwhile, I’ve ordered a set of lights – and the supplier will supply a high/low beam switching cable. And he’ll make the cable plug-play to whatever the OEM light output connector is. That’s awesome for me – but I don’t know what the OEM connector is, and my current / old harness has a round aftermarket 3-pin connector.

So does someone know what the OEM headlight connector that I’ll be getting with this harness (800.11.075.500)? Time’s tight, I can’t afford to wait until the harness arrives and then order the lights and cable. Hoping someone knows what that connector is. I’m guessing something along the lines of a KTM connector such a 2 x 3 Molex like this?

Any help would be much appreciated.

Thanks,

c

ede · Apr 17, 2018

Hi Canadius,

long story short - I don't know what's the correct connector your wiring harness requires! Just wanted to share a different approach

My 2002 FE 501 came with a piece of junk as wiring harness. Nothing except the headlight and the key switch was working (pics below). For offroad only it was o.k. to pull all the wires off the bike and run it with kill switch only. Since I like to rebuild it step by step I decided to build the wiring harness myself. Why?

Easier plug & play wiring (in case I would like to swap parts)
The original connectors are dirt collectors - You can find mud in every connector.... corrosion...
I would like to route the cables a little bit different than the original harness
Plug & Play for additional equipment, e.g. extra fans, etc...
most important: I like to do stuff myself

I'll do that in a 3-step-approach:

Wiring for functionality - everything should work - checking that I didn't forget a cable...
Preparing the cable conduits
Making everything looking nice with final cable connectors (super seal --> pictures below)

I actually tend to use Super Seal connectors since they seem to look good and come with double rubber seals against water and dirt (IP67). They're available for 1.5mm² cables - which are the most on the bikes. In case you like to buy them, use original AMP super seal! A friend of mine tried the chinese clone and they don't not really fit!!!

Regards,
EDE

AMP SUPER SEAL SPECS:
Usage: Automotive
Voltage: 24 V/DC
Amps: 14 A
Material: Polyamid
Temperatur range: -40°C ... +125 °C
IEC 529 and DIN 4050
IP67 (protected against oil, water, salt, ...)

canadius · Apr 17, 2018

Thanks Ede,

I'm going to modify the harness, and having used Super Seal connectors before, I concur.

In the interim, I need to know the OEM light connector, thought, to get the vendor to make me the connector to make things work for now. Over the coming weeks, I'll modify to suit - but with a ride a week and a bit away, I need to get the basics.

cheers,

c

OEM harness Headlight connector - 08 550E

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ede

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