82 850GL Resto...here we go

[Dogma]

...
Saw the factory splices and wonder if I need to check these as well.

I went through a similar process on my 1000G. I inspected every splice, and the only one that had any sign of trouble was the red power wire that carries the load from the R/R output. The soldered connection under the tape was starting to show signs or corrosion. My rearrangement of the charging system wiring eliminated the high currents at that splice, but I'm sure I re-made it. With lovely double-wall heat shrink tubing instead of tape. I will say though, the factory tape had done a good job of protecting all the other splices.

 

[Good Times]

I hope you have better luck with the Simple Green soak than I did. After about 5 hours, I still had to scrub and rub pretty good with a rag before anything came clean. If you are luckier, please tell me your secret.

The simple green did a really good job on the grease and dirt. I didn't let it soak that long. Only a couple of hours. It does not take care of residual tape adhesive though. I just happened to look over on my shelf where I had some Ronsonol. Fluid for my Zippo lighter. I keep a Zippo lighter not because I smoke, but because I think they are cool and I made it all the way to Weeblo in the Scouts and like to be prepared. :lol:

Here's a link for the Ronsonol: http://www.walgreens.com/store/c/ronsonol-lighter-fluid/ID=prod6021241-product

Anyway, the Ronsonol said on the bottle that it removed label adhesive. I used it on the sleeve and it cleaned up really well quickly. I'll use it on any other adhesive I come across that I want to remove.

Today, when I get time after the big Easter Egg hunt at church, I'll start cataloging the wires I need to replace and see if I can find the right colors and connectors locally. Then I'll shop online if needed.

 

[cowboyup3371]

Thanks Good Times, that's a great idea for removing that gunk (might want to throw it in the tips section).

 

[Good Times]

Wasn't able to touch the bike yesterday or today. Too much going on this weekend with the Easter Egg Hunt and Skeet Shoot. Both were a great success but cut into my bike time!

Anyone know where I can find white wire with a red stripe? Can't seem to find that anywhere. I need to replace mine in the harness.

 

[Flyboy]

GT, awesome progress, getting on with the wiring harness, I am still walking big, huge loops around mine. But yours is looking really good.
She is going to be something else when done.
Drop Hampshire Hog a PM for the place that sells the auto wire, all colors all sizes, anything you want.
They in the UK, but how much can it cost to ship a small roll across?

And be nice about the G....irls bikes :twistedevil:

 

[GateKeeper]

Wasn't able to touch the bike yesterday or today. Too much going on this weekend with the Easter Egg Hunt and Skeet Shoot. Both were a great success but cut into my bike time!

Anyone know where I can find white wire with a red stripe? Can't seem to find that anywhere. I need to replace mine in the harness.

Sorry but that right there, trumps any bike buiilding.....


glad to hear you had a good weekend, if my parts come in this week, I will have friday, saturday, sunday and monday, to work on the bike a bit, no regular work as it's Easter weekend for us here, only have to work my Dispatch gig, but that is OK, as it's over time......

 

[Steve]

I want to upgrade the electrical system. Planning on replacing the fuse block with a PC-8 thanks to Mr. Steve. I also want to install some relays. Not sure which ones to do though. Coil, headlights, horn, etc. etc. Suggestions, thoughts?

OK, you asked, here are my suggestions.

Relays? Only ONE is necessary. Just like the one installed in my fuse box thread.

Once you supply full power to the bike's harness (that you are cleaning up

), you will probably find that you don't need any other relays.

One possible exception would be one that turns the headlight off when you push the starter button.

.

 

[Good Times]

GT, awesome progress, getting on with the wiring harness, I am still walking big, huge loops around mine. But yours is looking really good.
She is going to be something else when done.
Drop Hampshire Hog a PM for the place that sells the auto wire, all colors all sizes, anything you want.
They in the UK, but how much can it cost to ship a small roll across?

And be nice about the G....irls bikes

Thanks Flyboy, the harness is not going to be as bad as I anticipated. I'm really glad. Just need to find the stock color wiring and the white with Red Stripe seems to be illusive. Thanks for the heads up with Hampshire Hog.

Oh and as far as the G's. Being such solid performers they can take a little ribbing from we "L" owners just to keep things interesting. Hey, we're all family! :lol::lol:

Sorry but that right there, trumps any bike buiilding....

glad to hear you had a good weekend, if my parts come in this week, I will have friday, saturday, sunday and monday, to work on the bike a bit, no regular work as it's Easter weekend for us here, only have to work my Dispatch gig, but that is OK, as it's over time......

Hey GK! If I couldn't work on the bike then smelling gun powder is a GREAT alternative. Feeling a tight line with a fish on the other end of it is as well.

With all that time to work on the bike you should be riding it to the range in a couple of weeks!

OK, you asked, here are my suggestions.

Relays? Only ONE is necessary. Just like the one installed in my fuse box thread.

Once you supply full power to the bike's harness (that you are cleaning up

), you will probably find that you don't need any other relays.

One possible exception would be one that turns the headlight off when you push the starter button.

.

You read my mind Steve. I actually think this may be my best option. Think I'll add some of the suggested grounds as well. I had a ground problem to begin with some where that had blown my running lights both in the tail light and gauges. I'll go with the PC8 and spring for their relay kit as well. Cleaned up the ignition switch already, just need to replace the connector that was melted.

Spring break is coming up with the fam. Just have to figure out which parts to pack so I can work on them at the beach.

 

[Good Times]

So I'm just minding my own business when.....

So I'm just minding my own business when.....

....my wife looks at me and says, "Hey, when are you going to finish the bike? You need to hurry up."



So I jump to my trusty laptop and start tapping away. Not long after that I'm yelling across the room, "Don't freak when you see an international charge on the credit card from a company called EBEAVER."

PC-8 and 18in relay kit ordered.

Now I will take inventory of the wires and connectors I need to replace and order everything from vintage connectors and the wire source they have on their site.

I've been trying to keep this thing on the DL as to not affect the cash flow too much. Apparently my wife was is not in favor of that. How awesome is she????!!!!

Note from the editor: She is apparently feeling pretty cheeky as well. As I'm typing this she says, "I'm going outside on a bike ride with E. You see, we have bikes that work." :lol:

 

[Guest]

Hahahaha awesome! Glad to see you getting motivated

 

[Good Times]

Spent some time soldering my connections tonight. Got to show my son what soldering is. He was pretty fascinated.

Got everything sorted for these connections.

Then I took a look at my solenoid and decided to replace the yellow/green wire and connector.

Started here:

Got the new wire soldered on and then the craziest thing happened. I looked over and sitting there all lonely was the polishing wheel, just calling out to me.

I had to get the panel ready for the new PC-8 that should be on the way.

 

[SVSooke]

You got to watch those wheels,they grab stuff

 

[Guest]

Great work GT. I'm so glad you are going first with the wiring harness so I can learn from following along.

 

[Good Times]

Great work GT. I'm so glad you are going first with the wiring harness so I can learn from following along.

Thanks Sci.

I'll be the first to say that it is a daunting task when you see all of those wires. I like diving in to stuff like that though. I want to know what makes everything tick, so what better way than to do a spinal tap on the ol' GS.

I think I'm doing it right. Or at least my version of "right." LOL But then again, I won't know until it has been down the road more than a few times.

 

[GateKeeper]

Way to go GT, it's one thing I did not want to do on my bike, and saw it really didn't need it, all was good, pliable, no hard spots, connections all seemed fine, cleaned it all up, a dab of di-electric grease for each connection, and some new electrical tape over the whole thing, made it at least look like new.....

You will at least get another 30 years out of that harness.....and your work looks to be of very good quality....

 

[Good Times]

Thanks GK. I thought mine was going to be in worse shape than it is. I was anticipating building a new one. SO glad that's not the case. I could have done it, but it would have taken me a while. I don't have too many wires that need replacing.

I am replacing the positive (red) circuit and the will probably go up a size in wire for the ground circuit (black/white) as well, while adding some new grounds.

We shall see....

 

[Good Times]

Spent my time today on the bike working with the wiring harness some more. Finished up three of the connectors by soldering the crimps and putting heat shrink on each wire. I rewired the power (red) wire in the harness. In order to do that I had to recreate the crimped splice in the wire. I have been looking for the crimp but can't find them anywhere. Not even vintage connections. I made an order for wire in the stock colors today from RIWS. They are one of the links on vintageconnections.com. I called and talked to them and they told me that they didn't have the crimp and that they just wrapped the wire, soldered it and put some heat shrink over it.... They do reproduction harnesses for antique Rolls Royce and the like. That's almost up to snuff for my '82 Suzuki right? So this is what I did:

The original on the left and the new wire on the right:

And the finished product after solder and heat shrink:

I also found out that my burned stator wires, melted ignition switch connector and non-working running lights were all related to an incorrect wiring job at the starter switch connecting block.

Here's the culprit:

I took this picture the first time I ever looked at any of the wiring about a week or so after I bought the bike. I knew it didn't look right. Now after looking carefully at the wiring diagram, whoever did this had the stator loop wired to the wrong leads and some other crazy stuff going on. Thus the burned circuits.

It's good to figure a wiring problem out. After I get my new wire I will have it fixed up right.

 

[JimmyR]

Wow - great stuff. I ended up redoing the whole harness on mine - partly because the original was in such a mess and partly because I thought it just be easier to work everything out if I started from scratch - then you don't have to check everything the last guy did.

Good to see solder on those wires too. It seems that the solder took to the wires ok - sometimes the old wire doesn't like being soldered - another reason to start again.

As far as grounding, I used a star ground under the seat and another inside the headlight. Both are connected to the ground point at the rear of the engine. It made grounding a lot simpler.

Glad you have a good wife - mine is awesome too! She thinks a bike project on the go all the time is a good thing. I think we both married well!

 

[Good Times]

Happy Birthday to me....

Happy Birthday to me....

Parts in the mail:

Tools:

And an awesome card:

Throw in the fact that it's Saturday, I'm with my wife and kids, it's sunny outside and you get one great birthday. Jesus does love me.

 

[Guest]

Awesome. Brought a BIG smile to my face Good Times. And yes he does. Thanks for the post.