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Rebuilding a 2004 FS650 - few electrical questions

Joined May 2015
62 Posts | 8+
Dublin
Hi all!

Long story short: I bought a what I thought was a 2004 FS650. Turned out the frame was, but the engine was a 1999-something-else. Cablework was butchered. I bought a 2006 engine, most of the loom, a new CDI etc etc.
My mechanic is trying to sort out the wiring now, but we have a few loose ends left...

First of all, the wiring diagram in the 2004 manual does not show the ignition barrel at all.
How do you connect the ignition barrel to the loom? I've an aftermarket one, and from what the mechanic says:
when ignition is turned on: "1 and 2 make no contact, 3 and 4 contact (no idea what that means; )"
with ignition off it's the opposite.
On the loom side, there are 2 yellow wires, and then a red and a white one joined together. Question is, which go where?

Question 2: there seem to be 4 cables coming out from the digital clock on the bike. One of them is pink and cut close to the clocks. The wiring diagram doesn't have a pink wire at all. Does anybody know where should it go?

Hope all of that makes sense :giggle:

We don't have a bike anywhere close to compare the wiring to, so there's a bit of guesswork there...
 
There is no ignition barrel on any of my 4 bergs. FS450C FE650e FS650C or FS650E (all 2005). You may want to take pics of the problem area (pink wire?)
 
In the 2004 user manual, the wiring diagram shows an ignition switch. The key ignition can be connected in a similar way. In fact, I think the only difference is that the one has a key and the other a toggle button, but they do essentially the same thing.

There is more than one way of connecting your key ignition, at the end of the day you want it to activate the killswitch (black/yellow wire to Brown), and open the connection to the 'energize starter relay'(White/red) when in OFF position. That Wht/Red wire is also for the start button, so running the start button Wht/red through the barrel switch will prevent the starter from being activated.
 

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