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80 to 83 fusebox upgrade help

  • Thread starter Thread starter refeicul
  • Start date Start date
R

refeicul

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I did the fusebox mod on my 80 1000gt i didn't really trust the mod so i got an 83 fuse box. After receiving it i realize it had its own connector but dont see a simple plug i can order. Has anyone done this upgrade?

Also I know i should look up the 83 wiring diagram just to me sure i hook things up right. with a continuity tester lol:p
 
refeicul said:
I did the fusebox mod on my 80 1000gt i didn't really trust the mod so i got an 83 fuse box. After receiving it i realize it had its own connector but dont see a simple plug i can order. Has anyone done this upgrade?

Also I know i should look up the 83 wiring diagram just to me sure i hook things up right. with a continuity tester lol:p
Click to expand...

You need the mating connector off of the GS1100E harness. Follow the wire colors and there should be a one for one match between the old and new style fuse box.

Realize there are going to be multiple red wires. You tell the difference based on wire gauge.
 
i can use a connector from either of these bikes
1elw7.jpg


but i will source out a connector. ill call neanderthal cycle salvage in cali to see if they will just sell the connector and not the whole harness.
 
refeicul said:
i can use a connector from either of these bikes
1elw7.jpg


but i will source out a connector. ill call neanderthal cycle salvage in cali to see if they will just sell the connector and not the whole harness.
Click to expand...

After about 82 there were a lot of gs's that used the same fusebox. Just do you know I have been producing a device called Solid-state power box. It requires removal of the stock connector. There should be plenty of them available from people they have cut them off. Only issue might be the lack of length. Even then there are probably crimp ends available to add your own wires with fresh crimps. Try vintage connections or similar.
 
I'm waiting to find time to install my SSPB, but I did a fuse block replacement before that. I asked myself why the fuse block had connectors and decided there was no reason other than Suzuki manufacturing logistics. The fuse block and harness were both permanent installations in my mind, never to be removed separately. So I skipped the connectors and soldered directly.

That was my choice. YMMV.
 
refeicul said:
i can use a connector from either of these bikes
1elw7.jpg


but i will source out a connector. ill call neanderthal cycle salvage in cali to see if they will just sell the connector and not the whole harness.
Click to expand...


no need to cut a harness to get the connector. its a standard Yazaki 8-position CNA-250 connector, available from Cycle Terminal, Eastern Beaver, etc. you will need an open barrel crimper
 
I think im going with a connector from cycle terminal they are in state and it should be here fairly quick.

Hey garagepunkfan i see you have a bike with this same fusebox can you take a couple pics of the plug so i can match it? It would save me a lot of time guessing and playing with my multimeter.
 
I'd go with the Solid State Power Box from Posplayr.
Awesome upgrade!
 
Something you can do that's cheaper than the SSPB but better than stock is to buy one of these.

They also come with boxes for only 6 and 4 fuses. I wanted the 8 for when I add some relays to my bike.
 
Triam said:
Something you can do that's cheaper than the SSPB but better than stock is to buy one of these.

They also come with boxes for only 6 and 4 fuses. I wanted the 8 for when I add some relays to my bike.
Click to expand...

I'm not sure that after market box it is better than a stock blade fuse box. Probably better than the old glass type.

I'm doing the last run of SSPB's so if you dont have an order in already then they are not available any more.
 
I put a 83 fusebox in my 78 1000,checking the wiring diagram the wires to it where exactly the same as the 83 750 it came out of.Yours really should be 1 to 1 just like posplayr said.
 
SVSooke you are correct if i where to purchase a wiring harness and clip the connector off it would be a 1 for 1 match or if one where donated. However I have purchased a virgin un-wired connector of which i have to crimp and wire up, which is why i asked for a few pictures to go off of to make my life a bit easier. Furthermore if it matched the oem connector that was originally on this bike its no longer there. it was melted and i have already done a mod to all those wires. They where not really shortened so i can still tell the oem wire colors.
 
refeicul said:
I think im going with a connector from cycle terminal they are in state and it should be here fairly quick.

Hey garagepunkfan i see you have a bike with this same fusebox can you take a couple pics of the plug so i can match it? It would save me a lot of time guessing and playing with my multimeter.
Click to expand...

sorry, my original harness was changed over for use with a Kawi ZX6 fusebox in 2011 so i don't have pics of the original setup
 
OK lets see if this helps:

Didn't quite understand why you where in such a tough place.Did I miss it in your OP?
 
well i did mention that it was mod'ed in my OP but i did not clarify as to the extent. In my project thread i do have a picture of it sort of i should of shown it here to show the conundrum i have to work with. And SVSooke that picture is exactly what i needed thank you.
 
Checked out your rebuild thread,yes that pic was enlightening.Was going to post that pic in my first post,not sure why I didn't:-k
 
posplayr said:
I'm not sure that after market box it is better than a stock blade fuse box. Probably better than the old glass type.

I'm doing the last run of SSPB's so if you dont have an order in already then they are not available any more.
Click to expand...

My bike has the glass type. I didn't know that any of the GS series came with blades.
 
Triam said:
My bike has the glass type. I didn't know that any of the GS series came with blades.
Click to expand...

On the 1100e from 82 on all spade type many others as well. They do not have the crimps and pigtails like the old style. Only thing to watch are contacts you can see from outside.
 
connector is wired and ready for install.
1zx2uy0.jpg


Ready for weekend soldering.:D
dgjbkj.jpg

Thanks for everyone's help!!!!!
 
NVM figured it out. The red wire with no continuity to the + on the front is to the Ignition Switch.

Ok im soldering it all up now i just have 1 more question.

On the wiring diagram for the fuse box it appears mirrored to what i actually see looking at the fuse box assembly so does that mean the right side of the 15 amp fuse goes to the ignition switch and the other to the battery? Or should i solder the red that has no continuity to the + on the front of the assembly to the Ignition Switch
 
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