SHERCO LIGHTING HARNESS REPLACEMENTshercousa.com/pdfs/ryp_wiring_installation.pdfYellow wire Red wire The 2 yellow wires and the red wire will be Yellow wire connected to the new RYP

7/17/2002 Sherco Wiring Installation

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SHERCO LIGHTING HARNESS REPLACEMENT

In response to the many requests from the field on how to remove the factory lighting and prepare the Sherco motorcycles for competition, RYP has developed a kit that replaces the factory harness and provides a kill button.

This kit is a “Plug-in”, you do not have to cut, splice or destroy the factory wiring.

The following pages will provide detailed instructions on how to remove the factory wiring and install the RYP wiring harness and kill button.

These instructions apply to all Sherco 1.25 – 2.9 motorcycles. The one shown in the pictures is a new 2002, 2.9.

If you have any questions or are not certain about any of the steps please call Ryan Young Products on 1-800-607-8742.


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Remove

This diagram is available on the www.sherco-moto.com website.

Go to “Support”, “Downloads”, “Spare Parts Books”.

Yellow wire

Red wire The 2 yellow wires and the red wire will be connected to the new RYP harness.Yellow wire

Remove Harness #6.9 and 6.11, you may also remove 6.12, this manual shows how to remove 6.9 and 6.11.


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These are the 2 harness’s that you will need to remove

Harness #6.11

Harness #6.9


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Preparation

The first step is to remove the rear fender.


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You will also need to remove the fuel tank.


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You may have to remove the fasteners from here.

In order to provide sufficient clearance for the removal of the taillight harness connector you may have to remove the two rear air box fasteners.


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Carefully disconnect all of the various connectors on harness #6.11 and remove it from the motorcycle. You can set it aside as it will no longer be used.


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You will need to remove the coil assembly, use a 12 mm, 6 point deep socket if you have it, if not very carefully remove the coil mounting bolt.


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Remove the headlight assembly and the front brake line clip. Keep the clip and bolt, you can install them on your number plate.


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Remove the headlight switch assembly, harness #6.9. You may set this harness aside also as it will no longer be required.


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Your bike should now look something like this! I know it looks a little scary but we will help you bring some order to this mess.

Look at the wiring diagram on page #2 and you will be able to identify the coil #6.2, the regulator #6.3 and the diode assembly #6.13.


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Coil #6.2

Regulator #6.3Diode #6.13

Main Harness from engine

Harness to the fan

This picture shows the components that should still be on the bike and are required for it to operate properly.


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RYP Wiring Kit, consists of a harness assembly and a wire assembly

Female Blade terminalMale Blade terminal

This is the main replacement harness, it basically takes the place of harness #6.11.

This is the wire assembly included in the kit that connects to the coil and the kill button wire.


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These 2 terminals connect to the thermostat

This terminal connects to the yellow wire coming from the regulator #6.3

This terminal connects to the red wire coming from the diode # 6.13

This terminal connects to the yellow wire coming from the main engine harness


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These 2 connectors will attach to the thermostat

Yellow wire connected to the regulator #6.3

Yellow wire connected to main engine harness

Red wire connected to the diode #6.13

This is how the new RYP main harness looks when it is connected to the appropriate components. At this point there you should have 3 wires connected to the components on the bike. The other 2 terminals will connect to the thermostat.


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Kill button wire attaches here

This picture shows where to attach the kill button wire assembly to the coil.


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The RYP kill button harness assembly connects to the open terminal on the coil #6.2

These 2 pictures show how the kill button wire assembly is attached to the coil and is ready to be connected to the kill button harness assembly


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This picture shows the kill button that is available from RYP, this kill button plugs directly into the wire assembly that was just installed on the coil terminal.


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Install the kill button on the handlebar, the harness is long enough that you can install it as shown or it can be installed on the handlebar near the clutch lever.


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Route the harness as shown.

Connect the bullet terminal to the black wire attached to the coil.

Connect the ring tongue terminal to the boss on the frame as shown.


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Connect the remaining 2 connections to the thermostat as shown

Connect the new harness to the thermostat as shown. These are the last connections you will have to make.


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Reinstall the coil and regulator as shown, it is a good idea to apply anti-seize to the bolt.


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The wiring should look like this at this stage of the installation.


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Zip tie as shown

Carefully and neatly place the wires as shown, everything should be able to be installed up under the coil and along the frame. After the wires are in the proper location zip tie them as shown, do not fasten the throttle cable, it should be free as shown.


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After removing the stoplight harness the stop light switch will remain.

The switch can be removed by holding the adapter and unscrewing the switch. RYP sells a replacement front brake adjuster bolt that replaces the switch and adapter.


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Reinstall the fuel tank and the rear fender and you are finished.

Make sure that the fuel tank does not interfere with any of the wires you have installed.

If you have any questions please call Ryan Young Products on 1-800-607-8742.

Documents

SHERCO LIGHTING HARNESS REPLACEMENTshercousa.com/pdfs/ryp_wiring_installation.pdfYellow wire Red wire The 2 yellow wires and the red wire will be Yellow wire connected to the new RYP