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how do i start and charge the new pig

  • Thread starter Thread starter 08rangerdan
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08rangerdan

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Im going to need help with this.. Ive sat down over the last couple nights trying to find a complete diagram with no luck for my 82 gs850g. Everything i found looked completely different then the systems on this bike. I went and carefully removed what was left of the original harness thinking i could simply chop out brakes and signal circuits. I also want to remove the neutral switch as i dont have any indication of it working currently. With this thing laid out on my bench im quite intimidated to start pulling wires without knowing what ties into what. I would love to run new wire and simply hook up a simple ignition circuit using the original coils, Stator, and ignitor. As i look at the cdi box i just see a bunch of wires and have no idea which leads will let me run the motor successfully.

Once ignition is resolved i plan to make a simple harness for signal, brake and horn etc. But ideally i want it split into 2 smaller harnesses to run into my frames for a cleaner appearance.. Ignition systems simply stump me and i refuse to start guessing
 
First of all, you don't have "CDI". That box is simply some transistors that take the place of points, and it is called an "ignitor".

Second, if you have stripped the wiring out of the bike, there isn't much chance of getting it running.

Removing a neutral indicator "because it's not working" does not seem like such a good idea to me.
Besides, if you live in a state that has vehicle inspections, it might not pass without a neutral light.

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Greetings and Salutations!!

Greetings and Salutations!!

Hi Mr. 08rangerdan,

You'll find lots of GS850G lovin' on my little website. Be sure to check out ALL of the information in the links below. It's your "mega-welcome". You might be surprised at what you find. :)

If you are here you probably have a 30 year old motorcycle that needs about 20 years worth of maintenance. In the links below you'll find maintenance lists, documentation, wiring diagrams, "how to" guides, vendor links, tips, tricks, and a whole lot of GS goodness. This is your "mega-welcome". Let's get started. :)

Let me dump a TON of information on you and share some GS lovin'. :D

I just stopped by to welcome you to the forum in my own, special way.
big_hi.gif


If there's anything you'd like to know about the Suzuki GS model bikes, and most others actually, you've come to the right place. There's a lot of knowledge and experience here in the community. Come on in and let me say "HOoooowwwDY!"....
hat1.gif


Here is your very own magical, mystical, mythical, mind-expanding "mega-welcome". Please take notice of the "Top 10 Common Issues", "Top 15 Tips For GS Happiness", the Carb Cleanup Series, and the Stator Papers. All of these tasks must be addressed in order to have a safe, reliable machine. This is what NOT to do: Top 10 Newbie Mistakes. Now let me roll out the welcome mat for you...

carpet.jpg


Please Click Here For Your Mega-Welcome, chock full of tips, suggestions, links to vendors, and other information. Then feel free to visit my little BikeCliff website where I've been collecting the wisdom of this generous community. Don't forget, we like pictures! Not you, your bike! :D

More links to helpful threads in the forum:
Help! Your Bike Won't Start
DON'T DO THESE THINGS
Help! Your Bike Won't Run Well
Oh God! Pods!


Thanks for joining us. Keep us informed.

Thank you for your indulgence,

BassCliff
 
When i pulled out the wiring i did label everything i could. If it comes down to it i could hook it all up on my bench and run the motor out of the bike

Thank god for the link and diagram! I came across that last night but couldn't find it again .
That diagram has alot of other systems not on my particular model... Makes my eyes go screwy looking at all of it
 
08rangerdan said:
When i pulled out the wiring i did label everything i could. If it comes down to it i could hook it all up on my bench and run the motor out of the bike

Thank god for the link and diagram! I came across that last night but couldn't find it again .
That diagram has alot of other systems not on my particular model... Makes my eyes go screwy looking at all of it
Click to expand...

What is on the schematic that you don't have?

This should be bare minimum if your include a charging system, starter and ignition.
 
Not the one you posted but the one posted before. Yours looks very useful to me i just don't quite understand the wording of it. In yours i read 3 leads from the stator shown as 3 yellow wires. On my motor i see 4 wires of different colours.. Blue, yellow, black and green (ground?). Is that true that the order of the wires is irrelevant? I really need to take a closer look at it when i can focus more on it
 
08rangerdan said:
Not the one you posted but the one posted before. Yours looks very useful to me i just don't quite understand the wording of it. In yours i read 3 leads from the stator shown as 3 yellow wires. On my motor i see 4 wires of different colours.. Blue, yellow, black and green (ground?). Is that true that the order of the wires is irrelevant? I really need to take a closer look at it when i can focus more on it
Click to expand...

Order of the stator wires does not matter. Also the stator does not have a ground. Sure you are not looking at the R/R?
 
The stator being the magneto device under the small cover on the right side of the motor that produces the electricity. That is the lead coming from there. I have 3 similar coloured wires from the top of the motor looking to be what i assume is the starter. Those go back to the rectofier.. Then things get unusual.. On the rectofier we have a green ground, black for power to the brake switch then a single red lead going up into the main harness via connector.. That connector has 3 more main yellow and striped leads which are cut flush. Not sure if that is something involving the neutral safety switch or what
 
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08rangerdan said:
The stator being the magneto device under the small cover on the right side of the motor that produces the electricity. That is the lead coming from there. I have 3 similar coloured wires from the top of the motor looking to be what i assume is the starter. Those go back to the rectofier.. Then things get unusual.. On the rectofier we have a green ground, black for power to the brake switch then a single red lead going up into the main harness via connector.. That connector has 3 more main yellow and striped leads which are cut flush. Not sure if that is something involving the neutral safety switch or what
Click to expand...
Well first of
#1 your stator is on the LEFT side of your bike, and the wire,s 3 of them should come out from either under the starter cover or the cover your shift lever is coming out through
#2 your ignition pick ups are under the RIGHT side cover , the little round one.
And from what I am reading above I believe you need to go to Basscliffs site and download a Free service manual on your bike and learn and understand where the different parts are located and what they do.
Not trying to be a Hard azz but you kind of need to know the parts before we can help explain their function and how to make them work.;)
 
Ahh ya that could be one of my issues. So new to this im going to be learning pretty fast. Maybe the 3 wires out of the starter cover is the stator itself then. I thought all the business was done under the cover on the right and just gears on the left. I've only ever worked on a 2 stroke 250.. Much less wiring. Only other wires coming from the left side bottom look to be what i thought was sensor leads but could be the starter.. Ill look into it
 
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hjfisk said:
Well first of
#1 your stator is on the LEFT side of your bike, and the wire,s 3 of them should come out from either under the starter cover or the cover your shift lever is coming out through
#2 your ignition pick ups are under the RIGHT side cover , the little round one.
And from what I am reading above I believe you need to go to Basscliffs site and download a Free service manual on your bike and learn and understand where the different parts are located and what they do.
Not trying to be a Hard azz but you kind of need to know the parts before we can help explain their function and how to make them work.;)
Click to expand...

.....and if you put your location on your profile, there just MIGHT be someone close by that's willing to give you a hand, or at least some guidance.

Now go back and read BassCliff's website again...ALL of it.
 
I wish that were a real possibility but the odds of running into that kind of help is priceless Haha. With some revised knowledge of the motor connections i feel better understanding the the basic starter circuit. Come Monday im going to take a trip and see if i can find any micro inline fuse holders and some smaller connectors to refurbish this harness as i begin to separate it.. Maybe someone has a link to the proper connectors and fuse holders ill need with proper names?? Knowing me ill walk into a electronics store and pick up things that won't be appropriate.. Consealable components are key to this project
 
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hjfisk said:
Not trying to be a Hard azz but you kind of need to know the parts before we can help explain their function and how to make them work.;)
Click to expand...

Ditto on this. I bought my GS850 knowing very little about motorcycles. There were three things that helped me understand how the bike works. In rough order of importance:

1. The factory service manual
2. This forum
3. YouTube videos

Before you go hacking up (or attempting to repair) the electronics, I'd highly recommend taking a week off from working directly on the bike and reading the factory service manual in your free time. Even the parts that you're not interested in right now, because eventually you will be interested in them.

When you come back to the bike, you'll look at it and go, "Holy crap! I know how this thing works now!"

EDIT: I re-read this and realized that it might sound like I'm implying that you don't know anything about motorcycles... I don't meant to imply such a thing at all. It may in fact be only the electrical side of things that you're less familiar with. Even if that's the case, I hope my advice is still helpful.
 
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Lol im not insulted by any means. I simply don't know much about motos and im reading everything i can and attempting to make sense of it all. Electrical drawings seem so obscure to me. Especially the lingo written on them.. I found a hi-res factory service manual last night which has a faintly readable drawing in it complete with the location of the original harness on the frames. I will need to print that off and start highlighting the circuits i want then start pulling them off the harness..

Since half of the connectors are in sad shape im going to need to redo the whole thing
 
There's a link to an 850GLZ wiring diagram on BassCliff's site, but it appears to be broken. You might PM him to let him know and ask if he has a backup copy somewhere.

Regarding the wiring diagram from the manual... yes, that one's a bit of a pain to read. I was suggesting reading the service manual because there are explanations and simplified wiring diagrams contained within that will help you understand how each electrical subsystem works.

For example, page 316 of the PDF (14-45 in the book) has an explanation of the electronic ignition system. You can probably safely ignore the narrative on how a transistor works (why they included that in the service manual, I have no idea) but down towards the bottom of the page they have a neat little diagram of the ignition system which clearly shows that the main components are the signal generators, the ignitor, and the coils.
 
i went and made up a 'rough' sketch. every drawing ive used has a different method of displaying the basic circuit but maybe someone can tell me if im close..

i tried to use as much of this drawing here

http://www.keepandshare.com/doc/4359880/550-schematic-reva-ppt-624k?da=y

but i ended up using the high resolution drawing for the gs850gl. the wire colouring was much more accurate for what i have.. compared to the 550 schematic.

here i attempt to create a basic ignition and charge circuit.. maybe not ideally organised but tell me what im missing if anything. zoom in on link.. done it on paint :/

bike is an 82 gs850g model

note: BLUE, YELLOW, GREEN, and BLACK lead on my ignitor to the SIGNAL GENERATOR,, doesnt compare to the 550 ignitor or signal generator diagram shown in link

note: all grounds or framed earths to be used as pictured


attached file:
 
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Hi,

eil said:
There's a link to an 850GLZ wiring diagram on BassCliff's site, but it appears to be broken. You might PM him to let him know and ask if he has a backup copy somewhere.
Click to expand...

Yes, I'll have to recreate that section of my little website. But I do have those diagrams backed up online.

Here's the unmolested diagram for the '82 GS850GL:

https://skydrive.live.com/redir?resid=2370B62DDF9F0C6B!1378&authkey=!AAf0ZHY1D53cclg

Here's a link to the diagram minus the auto-cancel turn signals:

https://skydrive.live.com/redir?resid=2370B62DDF9F0C6B!1377&authkey=!AIX31NG2rdIwsbs

*** minus auto-cancel turn signals, plus hazard lights, plus driving lights:

https://skydrive.live.com/redir?resid=2370B62DDF9F0C6B!1379&authkey=!AOzslcCre0V955A

*** minus auto-cancel, plus hazard:

https://skydrive.live.com/redir?resid=2370B62DDF9F0C6B!1380&authkey=!APpar032-23knAA

Thank you for your indulgence,

BassCliff
 
You are missing enough stuff to make the bike not legal in many States, not sure how many Provinces would also frown on it.
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.
 
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