[roadracer86]

Hi All,
Any of you guys install a Baja Designs light kit on a 2007 230? We purchased one and we wanted to discard the the stock rubber kill switch by the clutch and use the one on the left multi switch. The confusing part is the instructions for the kit where it states to disconnect the black wire with the white strip but when you get to the harness under the tank there are 2 wires that are black with a white strip. One for the key switch and the other for a ground for the stock rubber kill switch.

When I disconnect both of these leads I have two male and two female ends and only 2 female ends with the supplied harness from BD. This leaves the clutch switch and the one ground wire with no connection. Anyone else run into this?

Any help is appreciated before I call BD and get even more confused. Thanks all!

[gal8x]

I am unclear on…

This leaves the clutch switch…with no connection

which wire? G or G/R?

and the one ground wire…with no connection

from where, the BD harness? Clutch sw? kill sw? what color is it?

Therefore I can’t answer you definitively but maybe this will help. Ok grab your brain and hold on.

The B/W wires from the kill sw and the ignition sw both run to the same terminal on the ignition control module (CDI). The B/W wires are not ground but will stop the motor if shorted to ground.

The stop sw and the clutch sw both have a green wire that join at a connector. After that connecter the green wire runs to ground. The green wire is ground.

The neutral sw is the normal path to ground for the starter relay (G/R wire). Electrons pass thru the relay then the neutral sw to ground. The clutch sw provides an alternate path to ground when the clutch is engaged and the bike is not in neutral. The kill sw uses that same ground to short the B/W wires to ground stopping the motor.

Completely confused? Don’t feel bad. When I was taking electrical theory my instructor told the class “don’t try to understand this, just accept what I teach you as gospel and remember it. As you learn, understanding will come to you.”

[roadracer86]

Thanks,that helps me a bit since I don't have a wiring schematic for this bike.

I'm trying to shelve the three wire rubber kill switch and the clutch switch and replace it with the BD supplied lead from the 2 seperate wires coming from the BD left hand switch (seperate from the bundle connector). This BD harness is a two wire lead with one black w/white strip and one with blue w/white stripe. At one end of this lead on the black w/white wire is a male connector and a female connector. Essentially you plug on male end of the black w/white stripe wire into the BD harness from the BD hand control and the other end connects to one of the two wires on the bikes harness. I'll bad damned if I can figure out which one it connects to.

So at the end of all this I have on black wire with white stripe in the bikes harness with no connection and the green wires from the clutch switch is now disconnected since I removed the stock Honda bundle for the clutch and kill switches.

What I want to do is throw the stock Honda clutch switch wire and the rubber kill switch in the trash. Is this possible or am I doing something wrong.

Thanks.

[gal8x]

This reminds me of my dad when he would hand me a new model, the assembly instructions inexplicably missing.

I am sorry but I don’t have a clear picture of the BD switch assembly and its harness but I think this will help.
A volt/ohm meter or a conductivity probe will help identify what wires go where in the BD harness.

According to the 230 schematic, (mine is for an 06 but i bet the 07 is the same), you should have, on your stock harness, an empty [female?] two-wire connector (green wire {ground} & green w/red stripe {hot}) and a female single connector (black w/white stripe {hot}).
The bk/w is your kill wire. Run this to the new BD switch. Then you need the other BD wire from that switch to go to ground, you can use an empty stock green wire or you can splice into one. Don’t connect the Black w/White and the Green w/Red wires.

Concerning the clutch switch:
If you want the bike to be in nutral before it will start then tape the connector up. (You can use the green wire from it as mentioned above).

If you want the starter to engage regardless, then connect the green and the green/red. Then you can use the combination as a green wire connection for the kill switch. (As mentioned above).

If you would like I will PM you my address and invite you to use my trashcan to throw the old switches away in. I’ll pay for shipping of course.

[roadracer86]

That should help me; I have a Fluke meter I can use to check for voltage. Thanks for the help!