Anyone live in MA near boston area?

[Johnny K]

Is there anyone that lives in MA near the Boston area? I have had a problem with my bike and am completely stumped electrically. It's my wiring harness. My bike ran so good and now after replacing the dyna ignition, dyna wires and dyna coils my bike runs absolutely horrible. I did unwrap the whole wire harness and re-soldered some wires in the headlight bucket mess. I can't read a wiring diagram for the life of me. I was just wondering if there would be anyone who would be willing to come down and help me out.

 

[Johnny K]

My battery has died a number of times and have had to recharge and buy new acid for it. Would a bad battery cause a lot of electrical headache problems when you are trying to search for a solution? What kind of battery would people suggest I buy? I think I should rule out a 100% good battery and then try to solve my problems. What do you guys think?

 

[tom203]

Is there anyone that lives in MA near the Boston area? I have had a problem with my bike and am completely stumped electrically. It's my wiring harness. My bike ran so good and now after replacing the dyna ignition, dyna wires and dyna coils my bike runs absolutely horrible. I did unwrap the whole wire harness and re-soldered some wires in the headlight bucket mess. I can't read a wiring diagram for the life of me. I was just wondering if there would be anyone who would be willing to come down and help me out.

Didn't you buy another harness a while back? If so, why mess with old one? If you still have your old ignition stuff, put it back on and see if bike runs ok without fretting about the the rest of the electrical stuff.
Alternately, you could power the ignition circuit with jumper wires to see if bike ran better .
Don't be intimidated by electric stuff- just get a decent wiring diagram, one that's READABLE.

 

[tom203]

My battery has died a number of times and have had to recharge and buy new acid for it. Would a bad battery cause a lot of electrical headache problems when you are trying to search for a solution? What kind of battery would people suggest I buy? I think I should rule out a 100% good battery and then try to solve my problems. What do you guys think?

Yes, you need a good battery and it was probably stated months ago to check your charging system. Your harness is a mess, so it might cause this problem too. Your old video showed a bike running fast enough to charge the battery, so you must have charging problems.

 

[Johnny K]

Yeah I did buy a used wire harness, but a lot of questions still came up when i was trying to figure out where each wires went and so forth. I have a nice blown up wire diagram for the correct year of my bike. But when I try to compare it to the harness on my bike now it's fairly different and difficult to follow. The used harness I bought is also slightly different than my bike and the diagram as well. Just confused.

 

[tom203]

Yeah I did buy a used wire harness, but a lot of questions still came up when i was trying to figure out where each wires went and so forth. I have a nice blown up wire diagram for the correct year of my bike. But when I try to compare it to the harness on my bike now it's fairly different and difficult to follow. The used harness I bought is also slightly different than my bike and the diagram as well. Just confused.

Maybe the existing harness on your bike has been messed with by PO; the wire colors are similar across many models, so it should be relatively easy to determine what goes where, especially for critical systems like ignition and charging. Look at your blown up wiring diagram and compare it to this new harness- does it seem to make sense?

 

[Johnny K]

I'm going to look at it again sunday. Just been frustrated with the whole mess.

 

[tom203]

I'm going to look at it again sunday. Just been frustrated with the whole mess.

I know, but you got a great looking bike, so it's worth the effort to sort this problem out- too many of these bikes have had their owners give up on them for little problems.

 

[Johnny K]

Thanks Tom. I know I put at least $3000 into it over the past 3 years. The electrical wiring is the one thing I wish I re-did or at least wish I had no problems with at all. I am in too deep and the only thing to do is figure it out step by step. That much I know. But I am going to buy a new battery first.

 

[tom203]

Thanks Tom. I know I put at least $3000 into it over the past 3 years. The electrical wiring is the one thing I wish I re-did or at least wish I had no problems with at all. I am in too deep and the only thing to do is figure it out step by step. That much I know. But I am going to buy a new battery first.

You got it- "figure it out step by step" is the answer. Don't stare at whole wiring diagram, focus on one thing at a time. Figure out what wiring the bike needs to fire ignition correctly, then sort out charging system, etc. It's more challenging with a suspect wiring harness, but it's still a step by step process.

 

[Johnny K]

I've had these wires not connected at all on my bike for the longest time and now that I just bought a new battery, I am going to figure it out. Here is my problem: The signal generator (3 separate plugs) http://www.bikebandit.com/1982-suzuk...6124#sch264957
From the front part of the bike to the rear, the 1st plug set there are 2 wires (orange/white + black/white) That were supposed to go up towards the coils, but is mickey moused and is not connected at all. The orange/white wire next to the coils is soldered to (2 wires with a male connector). From my dyna S ignition red wire I have soldered 3 wires from the red wire coming from the ignition. 2 yellow wires going to either top terminal of the coil and then a wire with a crimped on female part plugged into the orange/white wires. I have the 3rd plug set wires (all solid colors) is not connected at all. The male plug is connected to the signal generator fine; but the wires coming out of the female part are not spliced/connected to any other wires. It's difficult for me to follow the diagram to find out where they should be connected to. When tracing the wires and looking on the diagram, there are a couple more splices that I can't figure out why they are there in the first place and so forth.

 

[tom203]

What fun! So you had ( originally) the suzuki ignition system with the timing advance built-in to ignitor, rather then the mechanically advanced system on other models.
Let's start with basics. When you turn ignition on, power runs from there thru kill switch via the orange/white wire to both coils and also down to ignitor box. Ignitor box receives the signal from the signal generator coils and then fires coils 1 and 4 ( or 2 and 3) by grounding out the other wire to coil. On my 650, a white wire goes to left coil, while a black/yellow goes to right coil-these have to get to ignitor box with good contact. Your colors might be different, but it sounds like your harness was messed with before you put Dyna system on. But the Dyna most likely used the existing wires to coils since they are ( or were) buried in harness. Check for good connections along these wires and along wires coming from signal generator coils.

 

[Johnny K]

Hey Tom,
Sorry about that. I am just really confused on looking at the wiring diagram and locating where the 4 cut wires I have and where they should go to. It is the 3rd plug and it has solid color wires (blue/green/black/yellow) I can't seem to find that plug and colors on my wiring diagram to see where they should be connected to. And then finally the black/white + orange/white wires that are not connected anywhere and I think should go to my coils.

 

[tom203]

Hey Tom,
Sorry about that. I am just really confused on looking at the wiring diagram and locating where the 4 cut wires I have and where they should go to. It is the 3rd plug and it has solid color wires (blue/green/black/yellow) I can't seem to find that plug and colors on my wiring diagram to see where they should be connected to. And then finally the black/white + orange/white wires that are not connected anywhere and I think should go to my coils.

Those solid colored wires are unusual. Do they run in or alongside the harness- can you find out where they connect at both ends? As I said, the original setup had the orange/white wire powering the coil + ( both coils) and also the ignitor box. Two other seperate wires went from ignitor box to coil negative spots. Just use the wiring diagram as a rough guide since someone has altered things .

 

[Johnny K]

Explanation with video

Explanation with video

I was finally able to take a video and explain my wiring problem from my new phone. Hopefully you guys can help me through this.

http://www.youtube.com/watch?v=ulqAFSPTCJQ

 

[tom203]

I was finally able to take a video and explain my wiring problem from my new phone. Hopefully you guys can help me through this.

http://www.youtube.com/watch?v=ulqAFSPTCJQ

Well, if a new phone can explain wiring, I'm asking Santa for one!
I will ponder this, but I'm easily bewildered on youtube- hopefully others will figure this out before I recover.

 

[tom203]

You probably thought I forgot about this! My computer didn't like it at all- had to use system restore to eliminate the gremlins. What little I saw was not helpful, but I see that your wiring is nasty. Will attempt to view again on Mac- maybe I'll be see more.

 

[Johnny K]

Okay thanks. I put the new battery in and she started right up. But sounds horribly boggle still. Thought maybe the new battery would change a little. It didn't.

 

[posplayr]

I watched the video and will try and a little.

First I hope you do not plan on rifing this bike with a bar harness, That harness has had all of the tape pulled off of it and now you are asking for problems running it. Once the wiring is sorted, pull the harness off and retape it and re install.

Second, all those solder balls you see were originally crimps to make common connections in the harness (e.g. like the big lump of B/W grounds) . It is standard practice to solder those joints to keep corrosion out. So other than the fact they are all bare there is no issue with that.

Third, do you have a Volt meter. If not get one.


Fourth. The Orange/White wire that had the solder ball near the coils is stock. It is powered from the right and switch. Confirm that using your volt meter.

The PO appears to have done the correct thing and tapped off of that O/W solder ball to with a blue wire and then ye;;ow to extend the power to the coils. And also ran an extended red wire to power the Dyna S. The Black /White is ground which is grounded to an even bigger blob in the harness near the air filters. This is all CORRECT.

The only other thing the Dyna-S install needs are the two negative coil wires. Those first two wire you are the White and the Black/Yellow again those are stock colors. And they simply need to be run from the Dyna S to the negative sides of the coils. W is 1-4 and B/Y is 2-3. Hook them up.


I still don't understand what has happened here. But somebody knew what they were doing buy apparently disappeared???

After the dyna -s is connected make sure that you get spark at the coil output. And report back without getting distracted.




Jim

 

[posplayr]

OK I see now you are running. That is good. Before you go too far do a quick charging test to make sure at least things are operable,

Want to just get a feel for how the charging is working? Do a Quick_Test

report back on that, before you tell us about those 150 mains?