New Member Hello and bare bones GS450 wiring help needed :)

[Guest]

First off, Hello everyone, and a little about my project, I hope you find it interesting! While I don't have a complete GS, what I do have is a mini buggy project with a GS450 motor wiggled in. The chassis is an ex sprintcar that someone tried to turn into a go cart, but failed miserably so I nabbed it and fabbed up dual front and rear a-arms, IRS, and a few other bits along with an entire rear frame to support the whole mess. The motor was running quite well before it was pulled from the bike, however now that it's ready to get it running again I've come across a roadblock, some of it from my own ignorance and haste, some of it from the PO's negligence. Problem is the old wiring harness was disconnected by me without recording where any of the wires connected (boo on me lol), because I thought 'they can only go back together one way"..... Bad move because now that I'm looking at it closely, many of the wires and connectors are so old, brittle and burned that most of it is disintegrating the more it's handled. And also there are many wires that were cut years ago and where they go is a mystery lol.
I'm guessing that most of it is not needed anyway, because all I need is for it to start, run a simple front light and of course charge the battery. No turn signals etc, is this possible?
I'll go ahead and tell what I have to work with:

1978 or 1979 GS450 motor, points and two coils - one coil is gray with two wires, one wire is orange with a white stripe and the other is black with a condenser attached (right on the coil itself, on the black wire) ; the other coil is black with two wires, one wire is brown, the other orange and no condenser.

Regulator has 4 wires, red, yellow, white with red stripe and white with blue stripe.

Stator has 7 wires and for the life of me I've googled and searched but can't find a schematic with this combination anywhere: blue, yellow with blue stripe, green with red stripe, white with gray stripe, green with blue stripe, brown with red stripe, red with black stripe.

Also from stator side a harness with 3 wires, yellow, white with green stripe, and white with blue stripe (I'm assuming it goes to the regulator)

And obviously, two wires from the points, one white (left cyl) and the other black (right cyl)

Does anyone have any idea how to wire this simply? I would expect it to be straightforward but the coils and the stator wires seem especially confusing especially because I can't find a schematic that matches, let alone a stripped down version. I have restored many vehicles in the past and had many dirtbikes and atv's and also raced for quite a while, but this for some reason has me stumped, I'm embarrassed to say lol,

My apologies for such a long first post lol

Cheers!

[posplayr]

This is a minimum schematic, mos tall lights and assundries are removed only what is on the list.

http://www.thegsresources.com/_forum/showthread.php?153727-Minimal-550-Bobber-Schematic&highlight=550+bobber

[Steve]

Greetings, welcome, and all that stuff.

Check again, you likely do NOT have a 450. They started in model year 1980, and never had points. Look at the base of the cylinders to see what number is cast there, or you can look at the serial number, which is on top of the clutch housing, right next to the oil filler on the right side of the transmission. Either of those numbers will give you a good hint to the size of the engine. As for year, up through '78, they were 400cc, '79 was the only year of the 425, then 450 from '80 until whenever they quit making them.

Your R/R is something I have never seen before, I don't recognize those color combinations. No matter, with your minimal electrical needs, you will want to change to a Polaris SH775 R/R, anyway. It will keep your stator from burning up with the reduced load. Yeah, it sounds backwards, but the stock R/R is a shunt-type regulator, meaning that any excess is shunted (shorted) directly to ground. The stator will be putting out maximum output ALL THE TIME, or at least whatever maximum it can, at any given engine speed. The Polaris R/R is a series-type regulator, which interrupts the stator current, reducing its average output.

As far as what you need to wire: obviously you will need your charging system. When you get your new R/R, don't worry about matching colors of the stator wires, they don't matter. Just connect all three stator wires directly to the three inputs of the R/R. The output of the R/R will obviously go to the battery and any loads (lights, etc.). You will obviously need a fuse and a switch for the lights. You will also need an ignition switch to control power to the coils, and a push button for the starter.

You will need your ignition system. There should be a wire that feeds power to the points. I don't know what color that is, as I don't do much work with points, but it's not going to be black or white, as they are the 'signal' wires that go to the coils.

No problem with the length of your first post, but you did forget at least one thing, ...




.

[mxscooter]

Well shave my head and paint me red it's a 425! Thanks for the pointer lol
And thanks for the schematic as well I downloaded it and will be staring at it shortly, so pardon my electrical ignorance, but what wire should feed the points and how should it and the wires connect to the coils, in particularly the condenser? I thought there would be two condensers but it was running with only the one.
I'll have to save up for the SH775 though, do you think I'll be OK for just a few rides around the yard without it?
Oh no what did I forget lol

[posplayr]

Well shave my head and paint me red it's a 425! Thanks for the pointer lol
And thanks for the schematic as well I downloaded it and will be staring at it shortly, so pardon my electrical ignorance, but what wire should feed the points and how should it and the wires connect to the coils, in particularly the condenser? I thought there would be two condensers but it was running with only the one.
I'll have to save up for the SH775 though, do you think I'll be OK for just a few rides around the yard without it?
Oh no what did I forget lol

You just need to read a schematic for that.

https://onedrive.live.com/?cid=2370B62DDF9F0C6B&id=2370B62DDF9F0C6B%211032&sc=documents&v=3

more stuff here.

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

[mxscooter]

Success! You guys are oozing with awesome thanks so much - I was able to get everything rigged temporarily and get spark from both coils, but only after having to pull apart and repair the solenoid which decided to stop working whilst in the middle of this whole thing lol. So, forgive all the questions but I have three more that I'm hoping you can answer, they might be simple:

While fiddling with the second coil, I noticed the first one started to get hot - I disconnected the battery before anything bad happened. After getting everything wired up, and both coils firing, I disconnected the battery just in case. I do however have a switch I'll be using as I get it permanently wired up.

Do I need a second condenser? The coil that is without one doesn't appear to be OEM. If I do need a condenser for this one, which wire does it go in line with, the wire from the points or the power wire coming in to the coil (the brown one or the orange one?) I'm not certain which wire is which as the coil works both ways, however I do know that there is a correct way to do it.

Lastly, the wires coming from the stator - are they all the same voltage? Steve, you mentioned a reduced load and resulting damage - can I use a wire to charge the battery, a wire for the headlights, and perhaps add a brake light etc for resistance?

I'll get some pics posted as things tidy up a bit, I hope noone minds that it has four wheels instead of two lol
Thanks again, and Cheers

[mxscooter]

No worries on the coil questions, I'll be needing to replace the aftermarket coil anyway - I was working on the machine last night and I started to hear a sizzling sound - before I could unplug anything I saw smoke coming from the coil and BAM it was fried up like a fresh chicken. lol
I was going to replace it with a factory one anyways oh well.
I did get it to run a bit, but the carbs are in need of a deep cleaning.