Reconnecting wiring

[Hummer]

Long-time lurker, first time poster...

I've been rebuilding a 1980 GS1000GL with a few minor changes. I just need a little reassurance on a piece of wiring that I've read up on repeatedly. So correct me if I'm wrong here...

The three yellow wires from the stator can be plugged in any order to the yellow, white/red, white/blue from the r/r. The extra red from the r/r runs up to a branch of the main wiring harness covered in a dust boot, correct?

Where I'm confusing myself here is with the additional 3 or 4 wires within that dustboot; I'm at work but I believe they are white/blue, white/red, green/white...I'll have to check. I have one wire within that dust boot that was originally disconnected, as well as one in the headlight bucket that was disconnected; I think this was the original loop that was perhaps disconnected by a PO.

If anyone has detailed pics of the various wiring harness connections, I'd appreciate it!

[Guest]

Here is a direct link to the service manual on Bikecliff's site

http://www.mtsac.edu/%7Ecliff/storage/gs/GS1000.pdf

It has a full wiring diagram


Link to Bike cliff's site

http://members.dslextreme.com/users/bikecliff/

[Hummer]

Thanks - I have a digital and hard copy of that manual, but I'm getting tangled up with the wiring diagram between the disconnected headlight circuit and my attempt at labeling all of my connections(the ink rubbed off a few). Here are a few pictures of where I'm at:

[Hummer]

This is the harness I'm usure of; I'm thinking that the red here connects to the red on the r/r and the wire at the top is the oil pressure wire, but where do the other three go? Seems to me that the white/red and white/green are the headlight circuit (and so should remain disconnected), but where does the yellow/green go?

[Hummer]

This is the boot the wires are in...I'm wondering if my harness had some extra work done by a PO. I have a yellow wire that runs from one of the guage handlebar plugs, that I now have connected to the starter solenoid. Does this have anything to do with the yellow wire in this boot?

[Hummer]

Alright, just in case anyone stumbles on this conversation with myself, I'd like to at least resolve the issue.

The yellow/green wire in that boot attaches to the starter solenoid. The red goes to the r/r, and of course, all three remaining r/r wires tie into the stator. The two white wires in the boot remain disconnected.

My problem was dim lighting and maybe the dimwit running the multimeter in the garage! I had run a yellow length of wire that came from another connection into the starter solenoid - wire color seemed to match in the dim light of my garage. This wire actually loops back into the harness and plugs into another wire coming from the left switch on the bars. After triple-checking everything with the multimeter, I finally found the start/end of each wire and figured things out.

[Hoosier Daddy]

I have an '80 GS750LT in pieces with the harness all labeled. Let me check when I get home... hopefulley they are the same.

[Suzuki_Don]

Sounds like you've got it all sorted. If you need any more assistance there are people here who can help. You might have caught them at a bad time. They might have all been on holiday.

Anyway that's a requirement of being on this forum "that you talk to yourself, ask questions to yourself and above all answer yourself". That's why our wives think we are all mad or they think the neighbour has come over for a chat when they hear voices coming from the garage/shed. I cover myself by saying "I had the radio on listening to the news".

[Hummer]

Haha - no worries - I know what it's all about. I usually figure things out sooner or later but a quick reply can save a few hours if the timing is right.

[BassCliff]

Greetings and Salutations!!

Hi Mr. Hummer,

There is a useless loop of wire going up to a non-existent headlight switch. When there was a headlight switch, this loop of wire would disconnect one leg of the stator when the headlight was turned off, to prevent over-charging. Now when you connect the three output wires from the stator directly to the three input wires of the r/r unit, you will have a couple of wires left over. Just tape them off and stick them somewhere out of the way. I explain this in my r/r replacement guide on my little website.

Anyway, let me dump a TON if information on you and share some GS lovin'.

I just stopped by to welcome you to the forum in my own, special way.

If there's anything you'd like to know about the Suzuki GS model bikes, and most others actually, you've come to the right place. There's a lot of knowledge and experience here in the community. Come on in and let me say "HOoooowwwDY!"....

Here is your very own magical, mystical, mythical, mind-expanding "mega-welcome". Please take notice of the "Top 10 Common Issues", "Top 15 Tips For GS Happiness", the Carb Cleanup Series, and the Stator Papers. All of these tasks must be addressed in order to have a safe, reliable machine. Now let me roll out the welcome mat for you...



Please click here for your mega-welcome, chock full of tips, suggestions, links to vendors, and other information. Then feel free to visit my little BikeCliff website where I've been collecting the wisdom of this generous community. Don't forget, we like pictures! Not you, your bike!

Thanks for joining us. Keep us informed.

Thank you for your indulgence,

BassCliff

[Hoosier Daddy]

Story of my life... too little too late.
Glad you figured it out.

[Hummer]

Thanks, BassCliff - I've been waiting for the official welcome!

I've been through the majority of the articles and a tonne of posts over the last year since deciding to rebuild my GS. Now that I'm in rebuild mode, I seem to forget where I've seen a lot of the info I need. It's great to have the service manual, but many of the pictures are just too dark to identify.

I'm happy to be part of the community - you guys have developed a great resource.

[DCrippa]

This thread has been helpful as I'm going through the same thing...

One thing I noticed on my harness is that I'm missing the attachment / wire that goes to the oil pressure sensor... I have the sensor - but not the end needed to fit on to it.. could I just solder the wire to it?

[Hoosier Daddy]

Mine just has a sepperate pigtail with an ring terminal for the sending unit and the other end has a bullet connector to go to the harness. Wouldn't take much to fab one up, even if you just get a short wire with a ring terminal on one end and solder the wire to the harness end, eliminating the bullet... it would still be removable for oil changes.

[DCrippa]

Why do you have to remove it for oil changes? Are we talking about the same sensor - the one on top right of the engine.

I don't have this plastic connector... for this sensor... http://cgi.ebay.com/ebaymotors/gs-55...s#ht_500wt_956

looks like this guy had the same idea of what I'm going to have to do...

http://cgi.ebay.com/ebaymotors/1981-81-GS550L-GS550-SUZUKI-Oil-pressure-sensor-_W0QQcmdZViewItemQQhashZitem45ecb35555QQitemZ300323919189QQptZMotorcyclesQ5fPartsQ5fAccessories#ht_500wt_956