Never Assume!!!!!!!

[Guest]

I broke the cardinal rule, wasted three days and got everyones nickers in a twist. Don't ever assume........check it out. I feel like such a twit....again. Refer to my previous post seeking help with my starter.

Well thinking that my starter motor's brushes were out of phase I decided to pull it out this afternoon (slow day at work) and as soon as I had the cover off I saw what was happening. Can you guess?

Yup it was wired wrong. The ground line from the battery terminal was connected to the power post on the starter and the power lead from the solenoid was fixed to the engine block. Damn how obvious. Reversed it and viola........got some engine turn over.

If I had followed the lines and not assumed they were going to the correct spots I'd have realised it right away.

So thanks to all who helped and now I think I'm back on track.Whew, dodge a bullet there.

Now to get some fire in the hole.

Cheers all, I'm a happy camper again

[49er]

Wow, that's "a trap for young players". Thanks for sharing your experience.

I followed your post, but couldn't think how it would be possible to reverse the polarity like that.

Reversing the polarity at the battery would have done some nasty stuff elsewhere!

[1_v8_merc]

Yup, can't assume anything on these bikes.

They are just older, and you don't really know until you rip it apart.

-----------
I almost installed a rear tire last night, that had no air in it!

It was really low-light conditions, and was distracted and not paying attention.

I guess the air had leaked over night, because the Bead Broke somehow.
(only ONE side of the tire broke bead.....so I didn't see it!)

I woulda been Super mad, if I mounted that tire and realized it was flat, haha.

[posplayr]

Wow, that's "a trap for young players". Thanks for sharing your experience.

I followed your post, but couldn't think how it would be possible to reverse the polarity like that.

Reversing the polarity at the battery would have done some nasty stuff elsewhere!

I shutter to think I dont know how he did not end up with a bunch of fired wire. Apparently Sprug doesn't have a ground wire from the battery to the R/R .

[Mekanix]

Reversing the polarity at the battery would have done some nasty stuff elsewhere!

Actually the only thing i can think of that could suffer is the ignitor and if you have a turn signal cancel device than it could also be damaged and maybe an aftermarket R/R.



Besides that everything else would work normally.

Lights, horns, relays don't care when it comes to polarity on these bikes.

Of course there are exceptions,

Starters

LED's.

Gas gauge maybe.


But anyways, Glad its fixed !!


This one's going in the record books :P

[spyug]

Actually the only thing i can think of that could suffer is the ignitor and if you have a turn signal cancel device than it could also be damaged and maybe an aftermarket R/R.

Dammit, I knew there would be something else to consider. I should have disconnected the ignitor while fiddling with this. I hope I haven't managed to toast it.

Well I'll know soon enough when I try and fire it up.

Keep your fingers crossed for me.

Cheers (I hope)

[posplayr]

Actually the only thing i can think of that could suffer is the ignitor and if you have a turn signal cancel device than it could also be damaged and maybe an aftermarket R/R.



Besides that everything else would work normally.

Lights, horns, relays don't care when it comes to polarity on these bikes.

Of course there are exceptions,

Starters

LED's.

Gas gauge maybe.


But anyways, Glad its fixed !!


This one's going in the record books :P

I'm amazed but I guess that is a good thing

[spyug]

Well I found it but as mentioned it did take out the igniter. So the hunt begins for another one and if I can't find one then I've got a load of parts to unload I guess. Bummer.

Spyug

[Buffalo Bill]

Me too!

I broke the cardinal rule, wasted three days and got everyones nickers in a twist. Don't ever assume........check it out. Yup it was wired wrong. The ground line from the battery terminal was connected to the power post on the starter and the power lead from the solenoid was fixed to the engine block. Damn how obvious. Reversed it and viola........got some engine turn over.

Yes, I got a bike for cost because it had a mystery problem, the PO thought it was a busted starter clutch because the starter would spin but not engage.
I took the starter out and just for curiosity spun the gear with my finger, it only spun in 1 direction?
DUH? I traced the starter cable to the solenoid and found them reversed, so the starter spun backwards!
Great bike with only 10,000 miles!
Bill

[JEEPRUSTY]

I broke the cardinal rule, wasted three days and got everyones nickers in a twist. Don't ever assume........check it out. I feel like such a twit....again. Refer to my previous post seeking help with my starter.

Well thinking that my starter motor's brushes were out of phase I decided to pull it out this afternoon (slow day at work) and as soon as I had the cover off I saw what was happening. Can you guess?

Yup it was wired wrong. The ground line from the battery terminal was connected to the power post on the starter and the power lead from the solenoid was fixed to the engine block. Damn how obvious. Reversed it and viola........got some engine turn over.

If I had followed the lines and not assumed they were going to the correct spots I'd have realised it right away.

So thanks to all who helped and now I think I'm back on track.Whew, dodge a bullet there.

Now to get some fire in the hole.

Cheers all, I'm a happy camper again

To be fair you made a presumption not an assumption.

[chuck hahn]

not a waste at all!! m you learned a bit about the starter clutch as well..

[spyug]

Thanks again for the kind words but its cold comfort if I can't locate another igniter. I've been researching for the last couple of days and it seems that nothing short of an original Zuk box for an 83 550 will work. There doesn't seem to be any interchangeability and it doesn't seem that there are any after market alternatives.

I'm wishing now that the starter motor or clutch had been buggered as those would have been easier to fix.

Well the hunt begins and in the meanwhile I guess I'll concentrate on the 750 tuneup and finishing off the Kat project.

Cheers all,
Spyug

[7981GS]

Wasn't there a 550 parts bike in the For Sale/Parts section not too long ago?

Daniel

[JEEPRUSTY]

So is this a 550 or a 750?

[Mekanix]

He has both Jeep,

A 550 with the starter and ignitor issue and the 750 with the usual cleanup and tuning to do.


I need to check some wiring diagrams to be sure but I believe that looking and the connections from your old ignitor and then compare them to any suzuki 4 cylinder ignitor from your year or earlier.

you could find the wiring diagram for the new ignitor and compare it to yours.

If It matches.

As in, they both have:

Non mechanical advance.

Wires For:

Power in
Ground
signal generator in
signal generator in
Coil 1
Coil 2


You could splice the wires from yours to those if the connector isn't a direct fit.

It would be best to get one from one that matches the way yours is set up.

I'll see what I can match up.

If anyone has any ideas?



Just did some research

So far: from the diagram from an 83 550es "which is all i have".

Ground is black with white stripe.
Power is Orange and white stripe
Negative for Coil for 1 and 4 is White
Negative for Coil for 2 and 3 is Black with yellow stripe
Signal generator Left Brown
Signal generator middle B/W
Signal generator Right Green White.

Drawing and manual suggests that it is a non mechanical advance.



If you just want it to run. It would with the one from my 400 :P there wouldn't be any advance but it would run