Minor Help on Motor swap (wiring)

[bietau85]

Okay im new so much help would be appreciated, Im near the end of completing my project but with at a brick wall right now. upon hooking up all the wiring i have 2 yellow wires from my Voltage rectifier left over and 2 wires that come from under my starter cover that i assume come from the stator (one i matched up already so 3 total). the thick gauge starter wire is on relay but the 3 from stator are different colors from any wire i have. I have a 1982 GS550M Katana motor i just fully rebuilt and painted. Im putting into my original bike which was a 1981 GS550T. I can get it to turn by jumping the starter relay but not by using my clutch switch which is in good working order, all in all im lost on where to go from here. i believe the VR wires and the stator wires is not completing a circuit i need but i need to know how these wires can connect and ive been trying to find info with no direction to guide me.

[bietau85]

the wires from the stator are yellow, white w green stripe, white w blue stripe. im pretty sure i got the white w green matched up but it could be incorrect since i noticed in previous posts that there are connecting wires that change color at the male to female receptacle point...the two yellow wires from the VM that are not connected are the 2 furthest away from the red one at the top end of the VM.

[Ranger]

CLICK you should find it there.

I looked for the page that may be helpful but couldn't find it and I smell brownies so I'm itchin to get into the kitchen right now.

Hope it helps and welcome, if you can't find it post again and by tomorrow morning you'll have 10 replies with the answer.

[Flyboy]

Welcome to the nut house, here you will find all the info you need and then some, these guys and girls are gurus when it comes to the GS, I don't know much about the wiring on the 550, but those that know more than me will be along shortly to point you in the right direction, Basscliff should be along in short order to give you his super, mega welcome, and a gold mine of information.

To get you started here is a link to the workshop manual

http://www.mtsac.edu/~cliff/storage/gs/GS550_77-82_all.pdf

and you may want to check out the stator papers here

http://www.thegsresources.com/garage/gs_statorfacts.htm

Oh, and we like pictures, lots of them, so let us see this bike of yours, sounds like you have done some good work on it.

[bietau85]

yea those 2 wires do connect to the VM and they are interchangeable as long as they are connected to the VM. but any who now i click the start button and nothing not a damn crank. it cranks when i touch post and it sounds great but something is up with the wiring, the guy that had it before me botched the whole grounding system up and i just have every ground at the same location basically, the motor ground is on the the battery negative, is that correct or is that suppose to be on the frame? (I can not remember)and the starter solenoid has to be gounded to the fusebox by the 2 mounting holes i believe... (correct me if im wrong) im just lost right now and just wanna figure out a way to start my bike without burning up my starter.

[bietau85]

yea Fly boy i will post pictures when all is complete. i have been taking pictures throughout the teardown and rebuild, im going for a very odd look on the the bike, its a either you like it or hate it kinda bike. the reason for the motor swap was because i took advantage of a guy who didnt know what he had which was a 1982 katana motor with 1200 miles for $50. now 2nd gear was mashed so i figured it was easier to swap motors. Cheaper also. then i saw it was a black motor, now my bike is black on black so i went with it, i tore down the motor to make sure everything was clean painted it black like it was but way nicer, then to put a cherry on it i dremeled the cooling fins i wanna say a lil under an 1/8" all the way around at angle and give it a sharp aluminum look amidst all the black. i just want this thing to run legit, no jury-rigged bs like the prior owner had going on.

[cowboyup3371]

Have you checked on your fuses yet? Not just looked at them but actually tested them with a light?

[bietau85]

checked them visually yes, with a light no. ignition lights turn on and everything else so i didnt take it much further. im done for the night though. im flustered, i dropped the motor last night and hooked everything up but today for 10 hours ive benn in the garage just staring at the bike aggravated, and disconnecting and then reconnecting. there is no need for this much wiring i keep thinking to myself.

[Flyboy]

Sounds like you have put together one sweet ride there, sometimes after hours of frustration it helps to just walk away, clear the head for a while, and tackle it fresh tomorrow, as far as the earths go, you should make sure you have an earth on the frame and on the motor, I run a nice thick earth strap from the motor to the frame.
Have you opened the starter switch to see that it is good inside, they get full of crud and oxidation from the years of living in the weather.
Check that your clutch lock out switch is not the problem, unplug the wires to it and bridge them over to bypass it, (if you have one)

[cowboyup3371]

checked them visually yes, with a light no. ignition lights turn on and everything else so i didnt take it much further. im done for the night though. im flustered, i dropped the motor last night and hooked everything up but today for 10 hours ive benn in the garage just staring at the bike aggravated, and disconnecting and then reconnecting. there is no need for this much wiring i keep thinking to myself.

Honestly, DO NOT TRUST A VISUAL INSPECTION. I learned from experience after fighting all day with my bike (just ran it the day before) when it would not start once I finished fixing a brake problem. Visually, my main fuse looked good - the wire was not broken nor was it burnt. However, after receiving help from Steve here, I determine the fuse was blown and done so under the metal caps . Once I replaced it, everything came to life.

I'm telling you this because everything you described happened to me. The starter would turn over if I jumped the solenoid ends; all lights and horn worked, the starter button did nothing. Take a few minutes and verify that fuse has power on both ends with a test light and not your eyes. Please, for your sanity's sake.

Also, remember your stator is nothing more than an alternator. If you take that out of the loop, your bike will still run but won't recharge that battery. You will just run down the battery. (IF I AM WRONG ON THAT THAN PLEASE CORRECT ME OLE GS gods)

[bietau85]

yea that makes alot of sense, it would be just my luck that the fuse would be blown under the metal caps. clutch switch is good so it better be them fuses. i really cant see any other reason for not starting.

[Flyboy]

No need to panic Scott, the wrath of the Gods shall not be upon you this day, you are perfectly correct in what you say.

And another good reason to change to blade type fuses.