Need help with brown wire

[pearljam724]

I removed a lot of parts over the winter to paint frame, etc. on a 75 - 550. I can't figure out for the life of me where this brown wire connects to in headlight bucket. Looking at a wiring diagram several times it appears that a brown wire is associated with the tail light. But, nothing adds up in reference to available wires, sockets, etc. A brown male bullet connector obviously inserts into the female end I'm holding in pic. But, no male brown bullet wire connection is available. I'd appreciate the help. A huge help would be someone peering into their 550 headlight bucket and verifying what this brown female bullet is connected to.

[GT750Battleship]

Hi,the brown wire is for European park light fitted to the bottom of the headlight,this also puzzled me 14 years ago on my GT750 I don't have the rest of it,no bulb carrier,just a hole where it's supposed to go,the taillight still illuminates when Key is turned to the far right position & removed Discount Bike Spares UK have it Suzuki part number 36118-04A00 bulb holder with two wires,one Brown & one Black with white tracer, around the £8 pound mark to buy.I can clearly see in your photo where the black wire with white tracer plugs into..near green plug !
Cheers,
Roger
GT750A

[Coyote]

Just been through all that PJ. The brown wire is not used on the USA models. You should also end up with an orange wire with a female connector with no mate. That is an accessory hot wire for the police model. Sirens, radio etc. With the key on, you will find a full 12V on that orange wire, but it is not used on the street bikes.
I guess Suzuki did it that way so as to satisfy all configurations with one common harness.

[pearljam724]

Thanks, for help gentleman. Huh, all my orange wires have mating connections ? You can see that one orange wire sticking up high above the rest. Maybe, that's why I keep blowing fuses ?

[yeadon_m]

+1 on the spare brown for parking lamp.

The orange you mention is, I think, for the lighting circuit. Unlike the 4 wire ignition switches on the GT750, the 550 and 380 had 6 wires, two of which are outside the block connector and carry lighting currents. Lord knows why Suzuki split these circuits on some but not other triples made in the same years!

I don't think I have a spare orange on my UK 380/550, but I might have forgotten.

Fuse blowing must be a short somewhere, almost certainly rubbed away insulation 'somewhere'. A pain to find until it happens all the time, when narrowing it down is much easier, by disconnecting everything, then reconnecting one by one until it blows again and the last one is the circuit to trace.

Cheers,
Mike

[Coyote]

You can see that one orange wire sticking up high above the rest

That connection appears to be correct as both have green sleeves. Maybe I shouldn't have mentioned the spare orange wire, but mine has one and everything works. Those orange wires are 'hot' with the key on. Maybe you should unplug all the orange wires in the shell and go one by one till the fuse blows. Have you replaced the fuse holder? If not, do yourself a favor and do so. Those crappy old feeble glass fuse holders can be part of your problem. They can be a problem all by themselves.

[pearljam724]

I made a couple corrections prior to posting this. But, haven't retried since then as I only had a couple of fuses to begin with and haven't bought additional ones yet. I believe I'm good now. One last question There is a 4 way female bullet connector. I understand the two black/white grounds attached to bucket mounting bolts are inserted into that 3 or 4 way. Any other wires suppose to be inserted into that 4 way ? There's a vacant female spot. I knew I should have taken pics prior. But, I've done this before. Thought it would be hassle free. I thought wrong, lol !

[bill in okc]

It looks like one side of your orange and red wires in the pic have lost their clear insulation sleeves. Maybe it is the pic but if they are really gone that could be causing random shorts and blown fuses.