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Noobie Question - Minimum wiring to make 78 GS750E run

  • Thread starter Thread starter tweekin2
  • Start date Start date
T

tweekin2

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Good day all -
Last weekend I picked up a 78 750 cafe project. The PO did a bunch of work, with only the wiring left to be completed (story sounded good).
The harness was completely removed to paint the frame.

So I have a question about shortest path to hearing it run.
I am pretty good with 12v wiring once I get past the charging system.

What is the minimum amount of wiring to make it run?
Looking for bare bones kickstart solution.
1. Stator wires to Coil (white/black)
2. Ignition cutoff switch to coils. (O/W)
3. Alternator 3 wires (yellow, W/G, W/B) to regulator's 3 yellow wires
4. Red wire from regulator to battery with fuse (what size?)

At this point I think I should have spark and battery will charge.

My reason for doing this temp solution is that I need to hear it run before I put any money into it.

This is my first "restoration" project, but so far it looks like fun!

Thanks in advance, as I know this smart group is going to be a wealth of information!

Cheers - Cory
 
Stator/Coil wires

Stator/Coil wires

Black/white from Stator to coils. Orange/Wht to kill switch.
 
wire up from stator to reg, then red wire to battery then connect coils to battery, make sure frame is earthed then give her a kick, u can put kill switch in the wire going to coil

this is just basic wire up to see if she fire
 
You don't even need the charging system wiring to fire it up. Just the ignition system.

Get the wiring diagram for your bike and trace out the ignition: points and coils. Pretty simple.
 
Thanks!

Thanks!

Many thanks, now off to the Fuel forum for hooking up the carbs :lol:
 
Regulator Wire hookup?

Regulator Wire hookup?

I have another quick question, with 3 yellow wires on the Regulator, does the hookup happen in a specific order? ie. first yellow to White/Gr etc.
 
tweekin2 said:
I have another quick question, with 3 yellow wires on the Regulator, does the hookup happen in a specific order? ie. first yellow to White/Gr etc.
Click to expand...
No particular order, but note that one wire disappears into the harness, then comes back with a different-colored stripe on it.
Skip that wire, connect all three stator wires directly to the three input wires for the rectifier.


As Nessism mentioned, though, if you only want to hear it run, just connect the ignition system and kick it to life.

.
 
Greetings and Salutations!!

Greetings and Salutations!!

Hi Mr. tweekin2,

Have a look: Simple Wiring Diagrams

[FONT=Trebuchet MS, sans-serif][/FONT]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!"....
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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...

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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

Thanks for joining us. Keep us informed.

Thank you for your indulgence,

BassCliff
 
Thanks BassCliff

Thanks BassCliff

I appreciate the welcome pack and have already been reading your information that you so kindly provide...

Cheers,
Cory
 
Suzuki's charging system wiring has some serious issues. It's strongly advised that you rewire the bike to eliminate the convoluted stator wiring. More specifically, route the stator wires directly into the R/R - do NOT hook it up into the factory harness.

Make sure the R/R is grounded to the frame or battery.

R/R power output can go straight to the battery with a 15A fuse in line, or you can route though the fuse box after verifying you have a low resistance path.
 
Last edited:
It might be advisable to go with more than a 15 amp fuse between VRR and battery (starter relay is a better connection as it avoids much in the way of connection issues). Even my anemic 1970's alternator makes a bit over 20 amps so theoretically could toast the fuse.
 
Normk said:
It might be advisable to go with more than a 15 amp fuse between VRR and battery (starter relay is a better connection as it avoids much in the way of connection issues). Even my anemic 1970's alternator makes a bit over 20 amps so theoretically could toast the fuse.
Click to expand...

The largest fuse in the GS fusebox is 15A. Does wiring the charging system direct to the battery change that requirement?
 
appears that there is no spark?

appears that there is no spark?

Thanks for all of your advise, I hooked up the coils to the black/white wires with 12v + going to O/W coming from a switch. I have verified 12v @ the coils, but when I pull a plug and check for spark I get nothing. I have verified this on both coils. Cyliners 1-4 to one coil, 2-3 to the other. Reviewing electrical diagrams isn't pointing out anything I am missing. Are there tests for the coils I can do?
thanks again!
Cory
 
Did you wire the points into the circuit?

BTW, what kind of exhaust are you putting on that bike of yours. You going to use a baffle of some sort?
 
Pics of my temporary wiring

Pics of my temporary wiring

Hey gang, I thought I would provide some pictures of the wiring that I did to get this running.

I took a generic switch with 12v to batt, switched went to the two orange wires on the Coils. Verified that when I turned on the switch these wires read 12v.

Took the black and white wires coming from points and hooked them to the same colors on the coils.

Turned the switch, grounded #4 plug, no spark. Tried the same with #1 and #3. Thus testing both coils.

I also made my own plug wires, and verified continuity from coil end to center of lug jacket.

One of my problems, is that I have never heard it run, so any of the parts could be bad, or need to be tested to prove they aren't the issue.

More head scratching tonight.

I will continue to search the forums for all the troubleshooting info that I can find. Anyone happen to live in Denver ;-)
I really don't want to take this to someone to sort out, but I am also worried wasting too much time chasing a broken part.

Thoughts?
Thanks again, Cory

Ed, once I hear it run I will be able to decide what my route on the exhaust will be. It doesn't have a baffle in the now, so I expect it to be LOUD. Looking at a new exhaust probably. This one seems to have about 2" of ground clearance, which will be scraping for sure.
 
Pic 2 battery and Sig Gen wires

Pic 2 battery and Sig Gen wires

Battery and Sig Gen wires going to coils.
 
Pic 3 Top view of Coil

Pic 3 Top view of Coil

Top view of Coil
 
You have the wrong coils if your bike has points. 3.0 ohm coils are for use with an electronic ignition.
 
Holy Igniter Batman...

Holy Igniter Batman...

Ok, so this may really show how little I know about this system.
Igniter, should this be going between the white/black from the points to the coils? I was just reading another schematic and Repair_and_Fault_Finding doc on BassCliffs site. And something caught my eye.

Do I need an igniter? If I do, that may be the problem. And it is certainly missing from my box of parts that I got with the bike. If that is only for later models someone please let me know.

Does anyone have some pictures that they may have taken during a rebuild? A pic is worth 1000 words.

More reading....
 
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