fjr clutch master

[Tapartacus]

Hi everyone, I am going to eventually install a fjr clutch master cylinder to my 92FJ (to match fjr brake master and get adjustable lever etc.). I understand that the switch connection needs modification. Has anyone done this? Is there a guide somewhere? Any help would be greatly appreciated.

Andrew

[Pat Conlon]

The FJR clutch switch needs no modification.
.....however there are 3 prongs or blades, on the FJR switch, where you plug your oem 2 wires in.
You need to get the 2 wires on the correct 2 switch blades.
Going by memory, I think it's the center and left blades that you use.
The center blade is common, and the left blade is normally open and the right blade is normally closed.
Again, I'm going by memory, I am currently out of town and can't check on my bikes, perhaps others can check my info..

To verify.....Just do a simple continuity test on your stock switch, and the same on the FJR switch, to see which blades to use.

Hope this helps...Pat

[Flynt]

the switch connection needs modification. Has anyone done this...

I did it on my '92.  The switch has 3 pins and you need the outer two, so you're 2 slot female will not plug into the correct pins as is.  You can plug it straight into the center pin and either of the outer pins, but it will not work in either of those positions.

I did the most difficult method I'm sure, but it worked...  I took the switch apart, removed the center pin, then rerouted the "bus bar" style connector for the furthest pin to place it in the center pin location...  dremmel and soldering skills required.  Now my stock 2 slot female connector snaps right in and even the retaining tab slots right into the switch housing.  There is a slight gap where the old pin was, so the solution below might be more elegant.

An easier method would be to get the matching 3-slot female connector (maybe this is not so easy?) and use the outer pin connections with your stock harness... wire cutters and solder/shrink wrap to produce a great result and the connector will fit in the switch better.

Lots of other ideas will work here, you just need to get the outer two pins from the switch connected to the slots in your stock connector.  Maybe you can post your solution for future reference?

Frank

[Tapartacus]

Thank you Gents, will post results when I'm done.
Frank, could you post a quick photo of your result when you have time?
Andrew

[Flynt]

Thank you Gents, will post results when I'm done.
post a quick photo of your result...?

well...  there's not much to see.  do you mean to open it up?

Frank

[Tapartacus]

No just a general photo of finished product. You know how much we love the photos. Not to mention how beautiful your fj is, I'm sure it's a top notch job.

[Flynt]

OK...  my strength is not photography, but here's a picture from the phone.  The things I like about this install are 1. the wiring harness from the new handlebar switch I installed didn't need to get cut, and 2. the plug still uses the "catch" mechanism that hold the connector in.  I tried to get a pic of the ~1/8" gap on the opposite side from this pic, but you can't see shit so I'll spare everyone the post.   



You can tell from inspection that the pin nearest the rider is the one you leave as-is.  Careful shaping of the housing internals and the copper bar inside the housing that connects the pin to the slider type switch is required and is fiddley to say the least.  Actual process involved dremmel, razor knife, a couple beers, some cursing and tossing about of shit, then some shaping and soldering of copper bits followed by more cursing and beers, then a miracle happened and it all fell into place and worked.

Good luck and let everyone know how you overcome.

Frank

[Tapartacus]

Great stuff! Thank you Frank, I'll be sure to remember the beer!

Andrew