What year's your 40? I ask as your switches may not match mine.
Attached is my most updated diagram. Happy to talk you through it if needed.
When I bought this cruiser the wiring harness was rigged for bare minimal necessary operation - the running lights and headlights were wired off the same stop (one click out) on the light control switch, and the hazards didn't work. The Hazard Switch and Flashers was a doozie to sort out. If you can do without Hazards in the short run, you can probably get the lights sorted pretty quickly.
Light Control Switch (which you've titled "Headlight Switch") - I think you're missing a piece that would connect to those 6 tabs on your switch. It would have 6 colored wires and run a short length (inch, maybe two) to a molded plastic connector that would then connect into the harness... maybe you can find it in the pile of your old harness. If not, you can probably jerry rig off those tabs to get it working.
The Light Control Switch should have two feeds coming in from the fuse block - original a solid red (R) wire and a green and red (GR) wire:
- The R was from the original Headlight fuse - I connected that to the Kwik Wire (KW) Red wire labeled "28 Headlight Switch Power", which originates at the fuse block from the fuse titled "Headlights".
- The GR was from the original Tail fuse - I connected that to the KW Blue wire labeled "7 Dimmer Switch Power". That worked for a while, then stopped. You can get by connecting both the GR and R tabs to the same 28 Headlight Switch Power, which is how my harness was set up when I got it.
so that's the power into the switch. In terms of power going out of the switch, you'll have three different wires (or maybe more, as a couple of the wires then split to go different places). For the Toyota harness, you'll have a red/white (RW), green (G) and red/black (RB):
- RW goes to your dimmer stich (I think that's on the steering column, but don't recall precisely. My RW wires were there, but had been cut, so I just spliced them back together. See below on the Dimmer Switch.
- G is supposed to connect to your parking lights, license plate light, marker lights, and tail light. On mine, that was connected to KW Beige "5 Low Beam", Blue "25 Front Right Turn Signal" and Light Blue "26 Front Left Turn Signal". There may be some other wires in there... I haven't dug into that part of the rat's nest yet.
- RB connects to the little light bulb in your Light Control Switch itself (I don't have that), the Combination Meter Light (i.e. the in your Speedo/gauges), heater control indicator light (and I don't have that either).
Dimmer Switch. It gets its power from a the RW wire coming off the Light Control Switch, and I think by design from the same R wire that goes into the Light Control Switch, but I haven't seen where that Red wire goes in on mine. Outgoing from the Dimmer Switch you'll have a red/yellow wire (RY) and red/green (RG)
- On my harness, RG is connected to KwikWire Tan "9 Low Beam"
- RY is connected to KwikWire Light Green "8 High Beam"
both go to the headlights
Brake Light Switch. Not sure about this one, but I can try and figure out what it's connected to.
