Wiring routing/locations/help needed (Warning: Many Pictures)

[CB700S]

Hi, everyone. I'm the guy helping one of your members, Krazy Kapitalist, put together his 1981 GS850G project. We're wrapping it up now, but we need some help to complete it, so here's our questions:

1. We had to remove what was left of the ruined/cut/butchered wiring harness and replace it with another, provided by a GSR member. However, since the prior owner had butchered it so badly, we don't really have a good idea of how the wiring harness is supposed to be reeved and routed through the chassis. Does anyone have pictures or diagrams of where the harnesses are supposed to route? I looked in the service manuals that we could find but I didn't notice anything useful. I'll post pics of what we have at the end of this post.

2. We have a headlight-type connector and a component that plugs into it back around the battery. It looks like it's supposed to mount to some tab somewhere but we can't find any mounting tab or anything. Below is a picture of it. Where does this go?






3. Just how many connections should we have to the battery terminals? We seem to have something like four possible battery terminal connections.

4. We also have what appear to be two screw terminals on the bottom row of the fuse box and the remains of some connectors that cracked off. What's supposed to connect here, if anything?


We also replaced the regulator/rectifier - sorry about those wires being in the way. Here's what we have.

[CB700S]

Here's one more - we are especially concerned with the routing around the steering head.

[azr]

If you go to Cliffs website you'll find the service manual in in it will be wiring routing diagram.

http://members.dslextreme.com/users/bikecliff/

for your first question, that 'component', which I 'think' is your turn signal relay, mounts on the right side of the battery box next to the turn signal control unit, although in one of your pictures it looks like you already have it mounted there.
If I remember right, if you have a stock wiring set up you should only have two wires connected to the batter, one for positive and one for negative.
I'm not sure what you're referring to with the fuse box question and there wasn't a close up picture of the fuse box.

Spend some time on Cliffs site and all your questions will be answered but to help you along here's a direct link the the cable routing and where things should be, it's for a 1000G but it will be the same for your 850.

http://www.mtsac.edu/~cliff/storage/gs/GS1000.pdf

[CB700S]

I have that service manual, but I guess I didn't see the routing diagram. Looked around his site as well.

Both of those tabs on the right side of the battery box are occupied by things that are actually connected to the harness. The component and it's connector are unaccounted for and there doesn't seem to be anywhere to mount it.

I'll post more pictures of the fuse box when we go back to work on it more tomorrow.

[azr]

It looks like you got a spare part with the bike then.....bonus

[CB700S]

Yeah, but both of those things are connected to the harness already. I still have this spare piece and socket. They plug together, but I don't see where to mount them.

[eil]

I have that service manual, but I guess I didn't see the routing diagram. Looked around his site as well.

The wiring/cable routing for the GS850G are on pages 12-28 and 12-29 (267 and 268 in the PDF) of this manual on BassCliff's site: http://www.mtsac.edu/%7Ecliff/storag...nual_HiRes.pdf

[CB700S]

Found them. We'll post more of that weird component-without-a-mount later today.

[azr]

Yeah, but both of those things are connected to the harness already. I still have this spare piece and socket. They plug together, but I don't see where to mount them.

On some models a relay connects on to a tab just above the rear rubber mount for the gas tank. You might try looking around that spot and see if you have a metal tab sticking out that that rubber mount will fit onto. One thing though, if you have found the connector on the wire harness that fits that relay you should be able to tell the 'basic' area you should be looking in, right? I think I'm confused. Anyways try that spot, if I remember right my buddy's 80's GS had one in that spot.