77 550 cafe project - couple questions.

[DCrippa]

Neither the Green/Red or the Yellow/Red go anywhere. On the wiring diagram, they seem to be extra wiring for an accessory or something. I have a dissected 550 harness at home I can use to double check for you tonight, if you wish (and if I can remember).

The headlight low beam is white. The high beam (and its indicator light) is yellow. The oil pressure light is powered by the Orange circuit and the Green/Yellow wire from the switch on the crankcase.

There's an accurate wiring diagram in the manual posted on BassCliff's site (pages 164 and 165 of the manual).

Weird cuz it seems to have an original white terminal block - I'll post some pictures so you can see where I'm at - pretty embarrassed by how sloppy it looks and have come to grips with the fact that I may have to re-do it or tear it up - luckily I have another stripped down harness from another member that came from a working bike - but wouldn't marry up to the gauges I'm using - if I end up going that route I'll probably look for those mini gauges and some plate for the dummy lights, though I do want turn signals and a headlight or the traffic around here.

I'll take a look again at that manual - been looking at it all day. I'll include a pic of the gauge - not sure what year it's from eBay auction said 550

Here's a pic of the wires in question - both ends are shown

Here's how my harness sits at the moment... Not too proud of it

Right side view

Left side view

Not sure what this is - is it a flasher?

Still gotta finish wiring the main connections - made an electric tray - have a few wires that I need to lengthen - and also had my neighbor weld me a new battery box - was gonna go under tail but I've just decided to keep it simple and located it close to the center of mass by the back of the motor - not sure if it's a bad idea as I've had a chain let loose on me before and crack a case - seems like it would hit the battery tray if that ever happens - I also plan on making a leather cover for the battery and just belting it down with a leather belt.

New battery tray location

It's all pretty ratty

Here are the gauges

And my latest lighting solution in order to mount the fairing...

 

[DCrippa]

Also picked up this relay for the coil mod

 

[Niklas]

Oh, I do not envy you that electrical jungle. Its the hardest part for me. Electrical systems. I had a diagram from the haynes manual GS1000 -78,79 and 80. Turns out that the diagrams are not the same. I wish you god luck with that jungle.

 

[Niklas]

"Just drew the pattern out with a Sharpie on cardboard as a template - eyeballed it on each side till it looked even...traced it (kinda wish I hadn't used the sharpie - but whatever it's committed me to a paint job later on down the road).

I could have been more anal about it but was already three beers in when I got going with it - so after that first hammer swing there was no turning back and I let her rip... "

- Thats what i like to do to. Have a couple of brews, grab a hammer and se where it takes me!
http://www.thegsresources.com/_forum/editpost.php?do=editpost&p=1566615

 

[oohsam]

Dont stress man, its not that hard, just logic. I built a brand new harness fro scratch following only manuals and had little to no experience with electrical. Piece of cake.

HOlla if you need a hand.

 

[DCrippa]

True - probably would be better easier and cleaner in the end but $$$
And its gotta be done on the cheap / resourceful side of things for now.

 

[boontonmike]

Let me know if you need a wiring diagram, I have the haynes manual I could scan it if needed.

 

[DCrippa]

Let me know if you need a wiring diagram, I have the haynes manual I could scan it if needed.

Are there any differences between the haynes and the clymer? I have the clymer. Thanks for the offer.

 

[Zafe]

im just about done with the wire tuck on my gs, while i was at it i wanted to clean up the bars, I took off the left hand controls and made started piecing together a switch harness. just gotta relocate the battery to the cowl.

so if you need some help identifying wires or what not, Im sure I can help


Vid of some wire tuckin:
http://www.youtube.com/watch?v=YWbKST36S78


And one for motivation?
http://www.youtube.com/watch?v=N3SuIFJZAX0&feature=BFa&list=UU5YrVWy0J3QJexdnTwcEJkA&lf=plcp

 

[DCrippa]

That's awesome I can't wait to hear that sweet sound out if mine - and more importantly actually ride it.

Haven't had time for much and it's cold as hell... Located my RR and solenoid today - right above the battery tray. Drilled a couple of holes in the plate where the gas tank tab comes down on to and mounted the solenoid off the inside - the pods should fit and hide it.

I will need some help with a few of these wires left in the pics in my thread - theres a few I gotta sort out by the tray and the front.

Pretty happy with how it's turning out: will need to strip and paint it and cut off unneeded tabs after it's all together.

 

[DCrippa]

Having trouble finding the corresponding connections from the fuse box the orange striped wires for each circuit don't seem to have a match on the harness - I really wish I could have spoken to the previous owner of this harness and gotten more details about its history. I double checked my eBay account and while the photos of the sale have since been deleted the description says 77 gs 550 harness BF. no idea what BF means ... And supposedly the gauges I got were from a 79. I didn't think the 79 came with gas guage / sensor. As mine has leads for one. Starting to wonder if they came from different year models.

So I'm thinking the O/R from the fuse box will go to the Y/R mystery cable up front - which should then tie into the ignition / starter switch.

 

[Zafe]

I can speak for my 0/R is a power lead to the left side hand controls, and also that light blue solid wire in the 2nd pic is a the lead to the thermal flasher or the blinker ill have to double check.

 

[DCrippa]

Thx so is that ming-yen part shown in the pics above the flasher?

 

[Zafe]

yes, thats a 2 prong flasher relay,

I dont think my 77 had the same one ill have to check it when i go see it again,

 

[DCrippa]

thx- got some time in the garage today - cut out some metal to match the seat bottom - My current design is to have the four posts of the airtech seat supported by washers and bolted to the pan / metal cut out I made today - and then bolting that to some old door hinges I have and then bolting that to the frame rail... haven't really figured out what to do for a latch... may just find a way to bolt it down or bug my neighbor to weld a nut to one side go through the frame into the nut on the underside of the seat... the seat is also sitting on the edge of the lip of the metal pan cut out... so a little fine cutting will be needed to get rid of the protruding lip around it... I'll try to post a pic soon. Far from actually attaching the seat but I just had to work on something else other than electrical today.

 

[DCrippa]

Will I need two flashers - or can that one do it for both front and rear signals?

 

[DCrippa]

Started on the seat / upholstery pan - figured I'd make it a two piece deal - maybe hinged so I can put stuff in the hump.
Scrapped the hinged idea just gonna make it plug in and fit tight - there's a plywood plug on the back part now.

And got these turn signals - but probably gonna put these on the fz since they're smoked and swap them for the clear ones I have on the fz in about this location? Still need to get a round tail light - I'm thinking one of those old Ford Model T ones could look cool. Well lost that eBay bid so a Harley '68 round light will have to do...

 

[DCrippa]

Quick question on the tail light... I plan to mount it inside the seat - flush more or less on the outside... but I've never cut fiberglass - how should I go about cutting the right sized hole in the fiberglass? I'm worried I'd crack it if I do it wrong... Would a regular hole saw for door knobs work? That was my plan.

Also I just realized that the inside marker light would be blocked by the seat pan if I recess the tail light - and there isn't much room for a license plate under the tail, at least I don't think so - and I'd have to cut out an opening in the seat pan to let that light through if I were to mount it under tail... quite a quandary not sure what to do - so I may have to look into putting a plate holder off the side of the wheel... Or is there a way to jack up the rear maybe get longer suspension - I believe someone recommended against going higher than 13" on the suspension.. not sure why though.

 

[ChicagoBob]

I'd use a light that can be mounted on the cowl with only small holes, like the Mike's XS British style light (at http://www.mikesxs.net/products-54.html#products). Check out replica antique car lights, also. See http://www.speedwaymotors.com/search-tail-light.html

 

[DCrippa]

I see - but I'm really set on the recessed / flush mounted look.