'81 GS 750EX is sicker than a dog and won't start

[Matchless]

I ran into a place that sells a new ignition switch for like 22 bucks before shipping for the gs 850 but I want my key to match everything.

The electrical switch part on the ignition switch is removable and to retain your key, just swop the little white box with the wires on the switch. It is held in place by one small screw.

 

[Badliltexan]

EGAD!! I took this bike last weekend on the handshake and promise that this bike ran...oh yes indeed, it ran...WHEN CHRIST WALKED THE EARTH *grumble*.
Far as I can tell, the last owner did squat- I've been tracing all wires from point A to point B to point C with my multimeter- have replaced scads of questionable wiring already (slightly melted, brittle feeling, etc.), slapped a new battery in, replaced battery end connections, replaced a crapton of connectors, bought new fuses during my lunch break today and will be pounding away on my bad girl soon as the rain lets up (too hot in garage for me).

Am finding some things that don't line up with schematics in Clymer color wise and am trying to figure out what is going where...have pulled all electrical tape off everything just to trace wires (six feet of the crap give or take-WTF?! Almost felt like using a blowtorch to remove some of it). Went and talked to my buddy at cycle shop- told me if I can get my bike working at some point, he'll hire me (har de freaking har). He muttered something about electrical being the worst of bike issues and that doing the detective work can make or break a person. I'm inclined to agree. I have no life anymore. It's being consumed after work by my refusal to let this thing beat me...

Will keep y'all posted on the developments as they come in or watch for me on CNN when I go postal on it.

...I have to hand it to you guys for having the patience to work on your own bikes, btw.

...I need a beer.

 

[Badliltexan]

It lives!

It lives!

I HAVE JUICE!!! I HAVE POWER!!!!!!! OH MY GOD!!!:dancing: The lights are on, the horn bleeps (I should say almost wimpers) and the turn signals work!!!

YOU GUYS SO ROCK!!!

Damn, I'm giddy here *giggle*. This is almost better than sex!

Gotta go- do more fiddling

Hugs to all y'all!! Talk to you soon!

 

[seuadr]

sweet! just takes paitence.. but when you do the job yourself, it means you know someone took the time to do it right.

i've heard the horns for our bike accuratly described as "the sound a duck makes when you stuff a sock in it's mouth and punch it in the stomach"

 

[Badliltexan]

i've heard the horns for our bike accuratly described as "the sound a duck makes when you stuff a sock in it's mouth and punch it in the stomach"

ROFLMAO!!! I reckon that's exactly how it sounds

I got her started- she kicked over right away- by all that's holy I'm beside myself!! This is freaking AWESOME!! Have to wait now for trickle charger to charge battery again as I sat there for too long jumping up and down like an idiot with glee whooping and hollering while admiring the shiny lights Betting neighbors think I have lost my mind. Good thing kids aren't home, they would have called 9-1-1 to report their mom has gone over the edge.

Next up- tank is going back on (started her without tank- on starting fluid because I just couldn't wait to see if she actually would start). Wish charger would hurry the hell up...

...now I REALLY need a beer :lol:

 

[biker_guy]

The electrical switch part on the ignition switch is removable and to retain your key, just swop the little white box with the wires on the switch. It is held in place by one small screw.

don't know why I didn't think of that. Had the thing taken all apart messing with a multimeter and a piece of wire. Didn't put 2 and 2 together.

 

[Nessism]

Good job! You've passed your initiation!

How are the carbs?...

 

[Badliltexan]

Carbs need cleaning- snagged hubby when he got home and informed him that we are going to spend Sunday working on my carbs seeing how I helped him rebuild his (translation: he cleans and I'll hold the screws *giggle*).

Why Sunday? Saturday we're going on a charity run. Was hoping to tool around on my 750...but since that aint happening just yet, I'll ride on his 1100GL. Can't bring myself to ride the CB360 anymore. It just seems so...small and powerless.

 

[Joe Guilbeau]

Carbs need cleaning- snagged hubby when he got home and informed him that we are going to spend Sunday working on my carbs seeing how I helped him rebuild his (translation: he cleans and I'll hold the screws *giggle*).

Why Sunday? Saturday we're going on a charity run. Was hoping to tool around on my 750...but since that aint happening just yet, I'll ride on his 1100GL. Can't bring myself to ride the CB360 anymore. It just seems so...small and powerless.

Be sure to set the floats 1st thing, then go to Wide Open Throttle, then mid range and finally idle set up. Thats the way Sudsco says to do it.

For your wiring woes, do yourself a favor and buy some barrel crimps (bare metal tubes you crimp onto stripped wires) then solder the junction after you obtain a satisfactory crimp (ratched crimpers work best). Be sure to place the heat shrink on BEFORE crimping and soldering

Then put a dollop of that "liquid electrical tape" to seal the crimp and solder...not too much, just cover to isolate from exposure to atmosphere.

Finally heat shrink tubing at least 1/2-inch past any exposed (now covered by liquid tape) junctions. You will never look back or have to re-visit that crimp for the life of the bike.

Guilbeau's my Name...
Electronics MY GAME...

Been an electronic tech since 1971 when I was working in the Oil Patch and fixed some errant wiring on the derrick. Naval training as a Interior Communication Technician, and a Two-Year Electronics Technology degree, with stints working for RCA Astro Electronics Government Systems Division in Princeton NJ, Schlumberger Well Services (Open Hole and then New Product Development), Biomedical Electronics at two Hospitals, Wayne Division of Dresser Atlas (magnets are magic on these things), Prototyping Automotive Wire Harnesses for E-Controls (conversion of Gas to Propane and multi-fuels...Ford, Chevy, Dodge, Toyota...etc), RF Microwave Debug Technician for SMT Transmitters/Recievers in the 6GHz t0 38GHz range.

...My bonafides above, 'jest so you know I ain't pulling yer leg on this wiring stuff....

Most of the connectors on our GS's are Molex (the HORROR!!!... the HORROR!!!...)

If ya'll really want to get the good connections going, replace them all with the WeatherPak series of commectors.

http://members.aol.com/bigturbo1/packard.html

 

[danex]

Well, I'm glad you got it working. =)

I wonder if the wiring is what could be wrong with mine... <scratches head>.

How's the beer?

 

[BassCliff]

Once uponn a time they lived happily ever after

Once uponn a time they lived happily ever after

I got her started- she kicked over right away- by all that's holy I'm beside myself!! This is freaking AWESOME!! Have to wait now for trickle charger to charge battery again as I sat there for too long jumping up and down like an idiot with glee whooping and hollering while admiring the shiny lights Betting neighbors think I have lost my mind. Good thing kids aren't home, they would have called 9-1-1 to report their mom has gone over the edge.

...now I REALLY need a beer :lol:

<sniff> I'm such a softy. I love a happy ending!

Thanks for sharing your good news and youthful exuberance. :dancing:


Thank you for your indulgence,

BassCliff

 

[Suzuki mad]

Well done.

Now, what bit did you change or notice that was out of synic with the wiring colours so this 'Old gril' started? Be nice to know.

The rest of it was FAR to much information of a non bike kind.

Suzuki mad

 

[TheCafeKid]

Wary be ye, as some of the wiring diagrams in Ye Old Suzuki bibles have a bit of misprints in them. Amazingly, they are all the same ones. Something about the wires in the gauge package being reversed...as per the manual. I will have to ask Steve again which it was...but the 850 and 1100g manuals both have the mistake in them. Dunno if it went as far as the 750 manuals. I will have to check my 750 man vs the 1100G man.

 

[Badliltexan]

For the love of God, Joe!! LMAO! Man, I figured there would be a better way to connect the wires than the stuff I've been using- thanks for that lead- will file that away for a rainy day But for now, what you suggested can wait (hope that procrastination doesn't bite me in the rear)- if I have to crimp one more wire, I'm going to scream.

Ignored the beer and went for the wine. Good thing my neighbors are wine distributors!

As for what was out of sync wiring-wise with the manual? Found a few wires that were one color into a junction, the other end came out a different color and were spliced onto several different wires that ran all over the damn place- some with no termination or spliced to other wires which in turn went back to original messed up wire further down the line. Found one wire spliced into two- both those ends ran into two seperate bolts on frame for grounding- that amused me to no end. The manual more than anything at least allowed me to figure out where what is going and how it all interconnects. Decided to stop worrying about the colors of the gazillion wires and just trace whichever new victim from the source and replace sections as needed.

Cleaned contacts on fuse box with wire brush and popped new fuses in too. All in all the electrical issues were certainly a combo of crappy wiring, wrong wire guage (found a few that I knew had to be a 14 guage not a 16), bad fuses and just plain wicked hack jobbing.

Carbs getting yanked out next for cleaning and rejetting. Was looking at the carbs and am wondering how much of a pain it's going to be to remove those given the tight fit of practically everything on the bike? The 1100GL was tight but I'm betting this one is going to more of a hassle. I'm not going to complain though, I'm just tickled she's running!

Decided after all this, I may follow the painting DIY I found on this site and repaint her too. That reminds me, have to post pics of her now and then pics later when she's in all her glory

Anyhow, thanks again for all the awesome help and guidance! Off to work I go, will touch base with you folks later! Have a fabulous day!!

 

[Guest]

Great Job

Great Job

Feels good----doesnt it. It is now officially, YOUR bike.

Sounds like my PO and your PO might be related.

As you know - your not done. But with the victory you get a second wind.

I'm grinning ear to ear. Had to laugh....your mind went right to the paint.

As Jimmy Buffett said "We do things for the stories we can tell". When your done you will have enough to fill a book.

Oh - and just dont have a beer......have a Guinness.

 

[Badliltexan]

Feels good----doesnt it. It is now officially, YOUR bike.

Sounds like my PO and your PO might be related.

As you know - your not done. But with the victory you get a second wind.

I'm grinning ear to ear. Had to laugh....your mind went right to the paint.

As Jimmy Buffett said "We do things for the stories we can tell". When your done you will have enough to fill a book.

Oh - and just dont have a beer......have a Guinness.

Steve- I've gone so far today as to match the crappy blue paint up and do touch-ups until I can devote the time to repaint my girl. Granted, the paint looks like crap but for now I can live with it So if any of you see me in NY cruising on an azure 750EX with a crappy paint job, feel free to laugh

Ok so here's another tech question- now that my bike is running, I noticed that the turn signals are not blinking. Could this be due to a bad relay or whatever that small black doohickey box is called under the seat? The lights come on but no blink. *sigh* No clicky clicky sound either from said box...

Got my new tail end in today with an intact rear light lens- happy as a pig in s#&t- gotta love Ebay- and yes, it works fabulous although it was a pain in the butt removing the rear cowl (that is the correct term, right?)just to swap out the light assembly.

 

[Kcwiro]

if both bulbs are on when you hit the signal switch (no flash) it won't hurt to try cleaning the light bulb sockets.. my 80 750EX *AKA Devil bike....long story* ran into this and all I had to do was clean the sockets a bit worked liek a champ. As they tend to get a lot of crap in there sometimes you'd be surprised what reseating the bulbs and a little cleaning will do. Flashers are cheap so if that fails see if you can buy one just for good measure. i found one for $5 =)

My old relay would slow down its flashing when it was raining surprisingly enough *guessing as it is a thermal relay* water was messing with it.

Good luck