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I was asked (and was paid $20 Wahoo) to put together a schematic for a GS550 Bobber project. I followed the GS550 Suzuki electrical design (mostly). I used the last schematic in the manual which is located in Bike cliff's website. The schematic could be made even simpler, but if it omits fusing and proper grounding then in my view it is "too simple". The schematic is intended to be taken literally as far as the physical layout and connections of the harness. So check the notes section that goes with the letters on the schematic and make note of all Ground symbols. Frame ground and case grounds have different symbols. The black dots show when connections between wires should be made; otherwise the wires are not connected. I used the OEM colors for each circuit as best I could.
The items included in the schematic are:
The OEM fuse box has unused circuits for things like lights.
The pdf file was created in Powerpoint so if someone wants that powerpoint file (PM me) they can change the colors of the wires for any other color sets they might want. The pdf of the version using stock colors is below.
The various symbols came right off the 550 schematic so if you study that and this you should be able to make decisions with respect to reusing old connectors or just wiring directly. Anything not connected is obviously not being used.
EDIT: THIS IS BAD LINK:
Here is the original powerpoint file that you can modify as you like. This includes a coil relay mod and some other changes.
A little discussion on lighting
The items included in the schematic are:
·Battery
·Fuse box (stock GS)
·Ignition switch (2 wire after-market)
· Kill switch and Starter switch (button) (OEM)
·Starter
·Starter Solenoid
·550 Igniter
·Coils
·Stator
·R/R (5 wire)
·Frame grounds
·Ignition Kill Switch
Some Notes:
·Fuse box (stock GS)
·Ignition switch (2 wire after-market)
· Kill switch and Starter switch (button) (OEM)
·Starter
·Starter Solenoid
·550 Igniter
·Coils
·Stator
·R/R (5 wire)
·Frame grounds
·Ignition Kill Switch
Some Notes:
- There are no lights/blinkers included in the schematic. Obviously they should be added.
Generally I would not run the stator leg through the handlebar switch (this is generally recommended on all GS's) but rather have the headlamp on all the time and direct connect the 3 stator wires to the R/R.
- No gages? You can add a wires for the coil (-) for the electronic tach, lights. (I left a ground in the harness running from front to back)
- This could be modified easily for a Coil relay mod. This would be simple to do now. (I left it out)
- There is an extra ground wire because some people may not have the starter solenoid and R/R mounted on the same plate. If you relocate igniter, solenoid, R/R to the same plate then things get simpler. Just make sure the Star grounding configuration at the R/R is maintained.
- Any other accessories can be added to the extra circuits shown
The pdf file was created in Powerpoint so if someone wants that powerpoint file (PM me) they can change the colors of the wires for any other color sets they might want. The pdf of the version using stock colors is below.
The various symbols came right off the 550 schematic so if you study that and this you should be able to make decisions with respect to reusing old connectors or just wiring directly. Anything not connected is obviously not being used.
EDIT: THIS IS BAD LINK:
Here is a Pdf version with much more resolution.
http://www.mtsac.edu/~cliff/storage/..._Schematic.pdf
http://www.mtsac.edu/~cliff/storage/..._Schematic.pdf
A little discussion on lighting
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