EVO: Electrical System - Sub-03C

Wiring of the Headlight Housing Connector

The original wiring diagrams do not have Pin# identificaitons. So in this description we will identify pin numbers for the internal connector (mounted to the headlight housing) starting with the Orange wires and looking at the connector from the backside, where the wires are inserted. We will call these four Orange wires Pin#1-4 follwed by the two Blue wires as Pin#5-6, naming them from left to right. The row of wires below that will be numbered Pin#7-12. To be clear, the Pin#1 is Top Left.

Of course, when looking at the backside of the external connector, where the wires are inserted, the pin location will be reversed, as they are counted from right to left. Just to be clear, the Pin#1 from the outside is Top Right.

(Note - This is NOT the way the Amp/Tyco Mate-N-Lok connector pins are numbered from the manufacturer.)

For 1986-1993, the Headlight Housing itself has a P/N of 67743-75. This housing, although it has an earlier -75 suffix, superceded the original version which was P/N 67743-84. The -84 version used a Speedometer cable retainer, P/N 56073-83. It is believed that the -75 version (used before & later superceding the -84 version) does not use this retainer. The -84 version was used from 1984 thru 1993 and sometime later the 67743-75 version superceded it. I expect because they didn't want to make one version with the retainer & one without it.

Another way of presenting this data is with a summarized functional listing of the connections on this Headlight Housing Connector:

Left Turn Signal uses Pin#5 & Pin#8 Pin#5 - sends power to the Left Turn Signal (BLUE wire on inside connector - BLACK wire outside) - This is not the blinking signal to the TS it is the power. Pin#8 - blinking signal to the Left TS - This is a BLACK wire with a VIOLET Tape Band. This same pin has a wire to one side of the TS Indicator.

Right Turn Signal use Pin#6 & Pin#12 Pin#6 - sends power to the Right Turn Signal (BLUE wire inside - BLACK outside) - This is not the blinking signal to the TS it is the power. Pin#12 - blinking signal to the Right TS - This is a BLACK wire with a BROWN Tape Band. This same pin has a wire to one side of the TS Indicator.

Oil Indicator Light (OL) uses Pin#2 & Pin#10 Pin#2 - sends power to the OL (ORANGE wire inside - BLACK outside) Pin#10 - active signal from Oil Pressure Sensor (GREEN wire inside - BLACK outside) (Gnd=LoOilPressure)

Neutral Indicator Light (NL) uses Pin#1 & Pin#9 Pin#1 - sends power to the NL (ORANGE wire inside - BLACK outside) Pin#9 - active signal from Neutral Switch (TAN wire inside - BLACK outside) (Gnd=InNeutral)

HiBeam Indicator Light (HL) uses ONLY Pin#11 Pin#11 - WHITE wire on the inside connector comes to it from the headlight bulb socket. It has power when the HiBeam is ON. The outside connection to Pin#11 is a BLACK wire that goes to the HiBeam Indicator Bulb (HL). The other side of the HL is grounded to Upper Fork Bracket. (NOTE: the actual Hi or Lo Beam power comes from the Left Handlebar Switch directly to the headlight bulb socket and IS NOT wired thru this 12-pin connector.)

Pin#3 - sends power to the Speedometer Light (ORANGE wire inside - ORANGE wire outside) The other side of the light is grounded thru the speedometer itself, thru the handlebar ground.

Tachometer Light & Signal uses Pin#4 & Pin#7 Pin#4 - sends power to the Tachometer Light (ORANGE wire inside - ORANGE wire outside) Pin#7 - sends the RPM Signal from the Ignition Control Module to the Tachometer (PINK wire inside - PINK outside) The other side of the light is grounded thru the tachometer itself, thru the handlebar ground.

(These are the orignal OEM wire colors - Since many bikes have been rewired over the years, your colors may vary and even the pin function locations may have been reorganized if your bike has been butchered (errr - customized).)

For 1993 (and presumably for 1991-1992) the wiring was a little different but all the same functions were implemented.

1993 wiring of the Headlight Housing Connector:

Mounted (inside) Connector 1 - ORANGE - Accessory Fuse Power to the front devices 2 - Also ORANGE Jumpered from #1 3 - Also ORANGE Jumpered from #1 4 - Also ORANGE Jumpered from #1 5 - BLUE - Lights Fuse Power to front lights 6 - BLUE Jumpered from #5

7 - VIOLET - From TS Flasher for Front Left 8 - PINK - From Coil for Tachometer Trigger 9 - WHITE - From Headlight HiBeam 10- TAN - From Neutral Switch 11- GREEN - From Oil Pressure Switch 12- BROWN - From TS Flasher for Front Right

External Connector 1 - BLACK to Neutral Light (power) 2 - BLACK to Oil Light (power) 3 - ORANGE to Speedometer Light (power) 4 - ORANGE to Tachometer Light (power) 5 - BLACK to Front Left TS Light (power) 6 - BLACK to Front Right TS Light (power)

7 - VIOLET - Left Turn Signal Flash (Gnd=ON) 8 - PINK - RPM signal to Tachometer 9 - BLACK - Power to HiBeam Indicator (when HiBeam ON) 10- BLACK - active Neutral Indicator (Gnd=InNeutral) 11- BLACK - active Oil Indicator (Gnd=LowOilPressure) 12- BROWN - Right Turn Signal Flash (Gnd=ON)

Headlight Housing Connector Parts:

The Mounted Connector on Headlight Housing: 72276-74 - Connector Shell using male pins 72039-71A - Male pin for Connector shell (x12) The External Connector: 72278-74A - Connector Shell using female pins 72038-71A - Female pin for Connector Shell (x12) 67839-74 - Weatherproofing boot for External Connector