Re-wiring my GS1100EZ

[Guest]

What begin as some touch up with the harness, evolved into a total re-wire when I find charred, brittle connectors all throughout the harness.

The bike had the original charging system components, ignition & coils so I decided to start saving $$ and go all out.

I have spent countless hours pouring thru the Electrical/Ignition forums trying to soak up info, since I am a total electrical noob.

The new parts list includes:

1.) New stator from Rick's Motorsports Electrics
2.) SH775 series R/R
3.) Dyna green coils
4.) New factory wiring harness

Wiring modifications include:

1.) Ignition system relay
2.) Wiring mods to the right hand switch recommended by Posplayr
3.) Stator wired directly to SH775
4.) SPG set up.
5.) SH775 will be wired into the 12V lead in the factory harness

As stated above, I am a complete electrical newb. I am slowly getting things put back back together & thought I'd document things here.

Please: any tips and critiques are welcome.

Trying to keep things as neat as possible...the SH775 is mounted on the back of the electrics plate. Fits nicely.

The wiring routed around the battery box is from the ignition.

[Rob S.]

A lot of fun getting to the battery on our bike, right? Even without the stock air box.

[posplayr]

There are a variety of things to do; without a schematic it is hard to tell what was done. Here are the primary thing to do.

http://www.thegsresources.com/_forum/showthread.php?218780-Gs1100ez-ed-relay-mod-tips&highlight=Relay+headlamp

http://www.thegsresources.com/_forum/showthread.php?218985-Simple-headlamp-relay-with-start-cutout&highlight=Relay+headlamp

http://www.thegsresources.com/_forum/showthread.php?123877-How-to-avoid-Starter-Clutch-Disaster-Modification&highlight=posplayr

http://www.thegsresources.com/_forum/showthread.php?229472-Custom-wiring-harness-or-Motogadget&highlight=posplayr

http://www.thegsresources.com/_forum/showthread.php?170746-Why-does-Suzuki-split-R-R-output-between-ignition-and-battery&highlight=posplayr

http://www.thegsresources.com/_forum/showthread.php?141055-Yet-another-Coil-Relay-Mod-(with-Dyna-S)&highlight=Relay+headlamp

[Guest]

Jim, I have several of those bookmarked already...they have been for awhile.

I have a schematic drawn on my whiteboard at work. I need to get a photo and post it up.

[Dodik]

invest in different colors wires or get a label maker, a year from now on you won't remember which wire which if its not labeled or has a different wire than the manual. Otherwise just keep going everything looks great, I am installing new to me used harness myself in a week or two. Thus far I only cleaned the harness so i can work with it without getting all dirty, next step is label every connection and then rewrap it.

[posplayr]

Jim, I have several of those bookmarked already...they have been for awhile.

I have a schematic drawn on my whiteboard at work. I need to get a photo and post it up.

I realize that, but have no way to answer your question based on the information you provided.

[Guest]

Well, I have returned to the land of the living!

Sorry it has taken so long to get a photo of the schematic in place, but life happens and projects are set aside for a time.

Here is the diagram for changes to a Single Point Ground. I really don't have any questions @ the moment regarding grounding, but anybody please feel free to point out mistakes, or suggestions for a cleaner install. Thanks for any advice/suggestions.



While it isn't in the diagram, the stator will be wired directly to the R/R. The relay is for the IGN system.

[posplayr]

If the SPG is a frame bolt, you are fine. If not I would add another wire from the SPG to a frame bolt.

At the SPG all wires should be stacked ring lugs (better contact between them)with dielectric grease, or as I have been doing I connect battery,frame and R/R(-) into a single 10-12 awg ring lug (at the SPG) and crimp and solder them. The rest of the grounds get stacked with dielectric grease.

I would also do a headlamp relay with the cut out; your starter clutch will thank you.