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#530437 - 02/26/14 2:04 pm 1977 TR7V headlight switchgear wiring in headlight  
Joined: Feb 2014
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TT Rider Offline
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Hi, I'm replacing the damaged original left hand Lucas switchgear on my '77 750 Tiger with a new Sparx item. The cables from the original connected to a 3-way and a 6-way white plastic pin connector in the headlight shell. The new switchgear has bullet connectors. Does anyone know where the white plastic connectors can be purchased (they could do with replacing) and how are the wires connected to the pins? Alternatively, is it simpler to just replace them with more standardised bullet connectors/another form of connector?

Also the old switchgear only had 5 wires connected to the 6-way connector while the new one has six - the additional one being white/green.

Grateful for any advice!




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#530472 - 02/26/14 3:54 pm Re: 1977 TR7V headlight switchgear wiring in headlight [Re: TT Rider]  
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Tiger -

Do yourself a HUGE favor and cut that plastic pin-connector out and get some proper Lucsr connectors/bullets to mate up with the Sparx switch. Those plastic connectors with the pins are POS's

Steve


'77 T140J
"Vintage Bike". What's in your garage?

"The paying customer is always right."

Fitting round pegs into square holes since 1961...
#530475 - 02/26/14 4:03 pm Re: 1977 TR7V headlight switchgear wiring in headlight [Re: TT Rider]  
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Hi,

Firstly, welcome to the Forum.

Originally Posted By: Tidza Tiger
Does anyone know where the white plastic connectors can be purchased

Sparx. smile

However, from personal, first-hand experience, mad I would strongly recommend against using the pin (AMP) connectors. Lucas supplied Meriden and Small Heath with individual bullets connections for years before starting to use the pin connectors from 1975; the pin connectors were such a warranty nightmare that the Co-op actually swapped back to bullets! shocked Pattern switch clusters come with bullet connections for a very good reason ... smile

When replacing the pin connections on the main harness cables, I recommend using these, crimped with the 'M'-shaped cutouts in a tool like this (there are more expensive/ better made ones smile ). There are bullet terminals that look like the Lucas originals elsewhere on your bike's loom but the modern ones are for metric-sized cables and your bike has slightly (but significantly frown ) smaller Imperial-sized cables.

Originally Posted By: Tidza Tiger
the old switchgear only had 5 wires connected to the 6-way connector while the new one has six - the additional one being white/green.

Did the old switchgear have a 'headlamp flash' - push the horn button upwards instead of inwards? The connecting cable into a small hole in the top of the horn button unit was often missed off. frown If not, and your new "white/green" connects to a Blue/White in the other part of the 6-way connector, you might find your bike now has an extra feature. grin

There should be White (power in to the horn button), Purple/Black (output to the horn), Light Green/Brown (input to the indicator switch), Green/White (mainly Green with a White tracer, output to the right-hand indicators), Green/Red (output to the left-hand indicators), Blue/Yellow (input to the dip switch), Blue/White (output to headlamp main), Blue/Red (output to headlamp dip).

Hth.

Regards,

#530477 - 02/26/14 4:06 pm Re: 1977 TR7V headlight switchgear wiring in headlight [Re: TT Rider]  
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L.A.B. Online content
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Norfolk, UK
(Stuart posted while I was typing)

Originally Posted By: Tidza Tiger
3-way


4-way? (but with 3 pins/wires)


Originally Posted By: Tidza Tiger
Does anyone know where the white plastic connectors can be purchased


The 2,4, & 6-way pin connectors can be obtained from Tri-Cor England (Sparx).

http://www.tri-corengland.com/acatalog/4-Pin-connector-SPX032.html
http://www.tri-corengland.com/acatalog/6-Pin-connector-SPX033.html

Originally Posted By: Tidza Tiger
how are the wires connected to the pins?


The pins/sockets need to be crimped onto the wires before the pins/sockets are snapped into the blocks.


Originally Posted By: Tidza Tiger
Alternatively, is it simpler to just replace them with more standardised bullet connectors/another form of connector?


Yes, bullet connectors are a better choice.

Originally Posted By: Tidza Tiger
Also the old switchgear only had 5 wires connected to the 6-way connector while the new one has six - the additional one being white/green.




Green/White is the colour normally used for the right hand indicator circuit and there should already be a switch-to-harness Green/White "pair" in the 6-way connector.

Could the "White/Green" in fact be a Blue/White wire, as Blue/White would normally be the "extra" switch wire.

Last edited by L.A.B.; 02/26/14 4:09 pm.
#530487 - 02/26/14 4:27 pm Re: 1977 TR7V headlight switchgear wiring in headlight [Re: Stuart]  
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Originally Posted By: Stuart
Did the old switchgear have a 'headlamp flash' - push the horn button upwards instead of inwards? The connecting cable into a small hole in the top of the horn button unit was often missed off. frown If not, and your new "white/green" connects to a Blue/White in the other part of the 6-way connector, you might find your bike now has an extra feature.


However, I'd hazard a guess that there probably isn't going to be any corresponding Blue/White "headlamp flash" harness wire to the 6-way connector (only the 4-way).


Last edited by L.A.B.; 02/26/14 4:31 pm.
#530546 - 02/26/14 9:09 pm Re: 1977 TR7V headlight switchgear wiring in headlight [Re: TT Rider]  
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TT Rider Offline
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Near London, England
Thanks everyone for the advice - much appreciated! I will be junking the AMP connectors in favour of bullet ones. Stuart (thanks for the welcome!)- yes, you're right, the Blue/White is the extra wire. The original horn button does press up for headlight flash,but has no wire connected. LAB - I'll need to check whether there is a corresponding Blue/White on the 6-way or the 4-way (yes, it is a 4-way not a 3-way!) Thanks for clarifying matters - I'd better get those Imperial bullet connectors ordered!




#530601 - 02/27/14 4:47 am Re: 1977 TR7V headlight switchgear wiring in headlight [Re: TT Rider]  
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Hi,

I sent you a pm about something else. You should see a flashing icon next to "My Stuff" in the top bar when you sign in, click on the down arrow and then on "Messages".

Regards,

#530682 - 02/27/14 4:16 pm Re: 1977 TR7V headlight switchgear wiring in headlight [Re: TT Rider]  
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Hello Tidza, I buy my bullets from Paul Goff:

http://www.norbsa02.freeuk.com/goffyelectrex.htm

..might be useful.

If you wish to sell on your broken left hand switch, I think I could use it. I only need the horn button bit - I am guessing it will be the same as my '81 Bonnie.

Bloody annoying, I sent the bike for a bit of top end work and they managed to break off the horn button (and lose a solenoid cover). It took me about 4 hours to botch up a soldered repair. It would have been easier to tackle the full job myself Anyway, just a thought.. and welcome!

#530718 - 02/27/14 8:32 pm Re: 1977 TR7V headlight switchgear wiring in headlight [Re: doug748]  
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TT Rider Offline
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Near London, England
Hi Doug - thanks for the link - looks good.

Currently got an interested party for the left hand switchgear but will let you know if I don't get rid of it. Not sure whether the horn button is the same as an '81 Bonnie though?




#530789 - 02/28/14 8:25 am Re: 1977 TR7V headlight switchgear wiring in headlight [Re: TT Rider]  
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UK Berks
doug,

is your switch a Norton/Trident/T140E type? or the flipper type?

I might be able to find a button. I bought a whole assembly on eBay for the casing. Due to stripped threads

#530795 - 02/28/14 9:01 am Re: 1977 TR7V headlight switchgear wiring in headlight [Re: AngloBike]  
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Hello Anglo. I will try to attach a photo:

......Failed with the snap! Maybe you can see it here:

http://www.flickr.com/photos/25720405@N02/12833936924/

It is part no: 60-7464 Handlebar switch left hand

Last edited by doug748; 02/28/14 9:10 am.
#530798 - 02/28/14 10:02 am Re: 1977 TR7V headlight switchgear wiring in headlight [Re: TT Rider]  
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I'm Dave m on Triumph Rat but somebody beat me to it here.

I have the RH switch but I'd bet the button is the same part.
I will need to search the garage for it, as it was a brainwave a year ago that somehow got stalled.

#530826 - 02/28/14 2:06 pm Re: 1977 TR7V headlight switchgear wiring in headlight [Re: AngloBike]  
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Norfolk, UK
Originally Posted By: AngloBike
is your switch a Norton/Trident/T140E type? or the flipper type?


A '77-'78 T140V/TR7 would usually have the T160 style LH switch assembly.

http://www.classicbike.biz/Triumph/Brochures/1970/77ModelsCanadaTri.pdf

http://www.tri-corengland.com/acatalog/SPX007-T140V-T160-LH-Switch-Gear--SPX007.html




The difference being that the original T160 LH switch assemblies (and pattern items) have the headlamp flash function whilst the T140V/TR7 assembly apparently didn't.


#530907 - 03/01/14 3:00 am Re: 1977 TR7V headlight switchgear wiring in headlight [Re: L.A.B.]  
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Hi Les,

Originally Posted By: L.A.B.
The difference being that the original T160 LH switch assemblies (and pattern items) have the headlamp flash function whilst the T140V/TR7 assembly apparently didn't.

As a matter of possible interest, 'early' T160's don't have the headlamp flash connected either. I wonder if it was an assembly cock-up at Lucas, some 'wrong' ones were then put on the shelf when the mistake was rectified and later the newly-fledged Co-op agreed to take 'em, possibly at a knockdown price?

Regards,


Moderated by  John Healy 


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