Starter Interlock Switch (as per the wiring diagram for a 82 gs1100EZ

[timbaux]

I got two wires coming from the right handlebar switch (from the start button) and i am trying to figure out where the go.. one is orange/white, the other is yellow green, I know what they are for. I know the yellow/green goes to the solenoid located by the fuse panel. I know the orange and white comes off the fuse panel and connects to the igniter and one side of the coils. The problem is there is a "starter interlock switch" that switches the yellow/green wire from the solenoid before it goes the starter button. I also am trying to figure WHERE to tap in the orange/white... i bought a switch and the wires were cut. No plug on it.

Where..and what does the starter interlock switch look like? It is NOT the solenoid, and it is NOT the key switch.

As for the other issue, the front brake handle switch that makes the brake light come on, i cannot find where that ties in at.

Any help appreciated.

[Steve]

The "starter interlock switch" is in the left clutch handle housing, near the pivot. The yellow/green wire comes from the starter button on the right hand grip, through the interlock switch, THEN to the solenoid. The interlock switch requires you to pull the clutch lever any time you wish to use the electric starter. Many of us bypass it by disconnecting the yellow/green wires in the headlight housing, then re-connecting the two wires that are part of the main harness.

The front brake switch is in a similar location on the right side. There will be an orange/white wire and a white wire in the headlight bucket.

.

[timbaux]

Tha k you for the response that is exactly what i needed to know.

[timbaux]

Ok i went over to work on the bike.. i got some issues.. first of all, the switch coming from the right hand switch (the pushbutton, ON switch, etc) has TWO orange/whites and a yellow green. I connected the yellow green from the push button straight to the yellow/green on the wiring harness that goes to the solenoid, and i know that is right. But... what do i do with two orange/whites?

Another issue is there is a plug with orange and white from the main wiring harness and a few other wires, i think seven others, in the headlight bucket with a plug on the end. Am I gonna have to cut the plug off and tap the wires I need? I dont know what the previous owner did. I know sometimes there is an overabundance of wires for the sake of the faired ES models. Mine is an EZ.

Still have to look for the wires for the front brake switch...

[Steve]

... first of all, the switch coming from the right hand switch (the pushbutton, ON switch, etc) has TWO orange/whites and a yellow green. ...

If you look carefully, one of the two orange/white wires should have a red band near the connector. That is the 'hot' wire, or the power IN wire that comes from the fuse. It goes to the 'kill' switch. The other orange/white wire comes off the 'kill' switch to feed the coils and the ignitor. It does NOT have the red band.

By your description, it seems that the wiring has been butchered a bit? On the main wiring harness, find the connector that mates up with the one from the right handgrip, the one with the yellow/green and two orange/white wires. One of them should have a red marker on it. Guess where it goes? If you don't see a red marker, use your test light to check the two orange/white wires on the main harness. With the connector to the right handgrip separated and the key ON, one of the two orange/white wires should have power, the other one not. That is the one that should have the red marker.

I know sometimes there is an overabundance of wires for the sake of the faired ES models. Mine is an EZ.

The "faired ES models" don't have any more wires than any other bike, and the "EZ" you describe merely says that it is a chain-driven '82.

.

[timbaux]

Thanks i am going to look at it in the morning. I see how it works now. Going to have to home out the incoming power. This bike has sat since 1991. I am almosy finished putting it together. Got tje frame powder coated and thats something i do not regret at all. Came out great.

Thanks for the help. I will see what i can find out tomorw

[timbaux]

Ok, i went over to the place where the bike is and got a good look at it. i got the front brake switch wires plugged in.

I have a plug that has about seven wires on it.....

Orange/white HOT
Orange/white for coils and ignitor
Orange/red to power and the left hand switch ( think this makes the headlight go out when the starter turns the motor over)
Gray for the license plate light, spreedo light, and tach light
Lightgreen goes to the stator
white/red goes to the regulator rectifier
Orange/green goes to the turn signal control unit

Alll of these wires are in a plug, and i have no plug that fits into it. i dont know if these are just wires that are going to light up in the instrument panel or what. Am i to cut the plug off and individually tap wires? to what? If you look at the diagram, the Right Hand Switch, all i have coming from there are two orange/whites and a yellow/green.

[Steve]

The orange/red wire will not turn the headlight off unless somebody has re-wired it. In its stock configuration, the orange/red wire runs from the lights fuse to the connector to power all the lights (except the tail light). At the connector, the orange/red wire will split off into yellow for the headlight and gray for the instrument lights.

The light green wire does not go to the stator. It is the wire for the left turn signal.

The white/red wire does go to the R/R, but your bike would be better off if you did some re-wiring to eliminate it. There are three wires that come out of the stator, you can access them under the airbox or battery box. One of the wires on the original stator is white/green and mates up to a white/green wire in the main harness. That w/g wire goes up under the tank, then turns around and comes back as that white/red wire, which mates up with a w/r wire that goes to the R/R. If you have an aftermarket stator, all the wires might be the same color, so don't worry about that. Take the w/g and w/r connections apart, connect the stator wire that was connected the w/g connector and move it to the w/r wire that goes to the R/R, eliminating that useless loop under the tank.

.

[timbaux]

Thanks again for your response. I truly appreciate it. After you explained it the diagram became a little more clear.

There is no motor in the bike. It has sat since 1993, and I am about to build the motor, but I had the frame powder coated and now putting it all back together.. other than the front brakes, all i got left if the wiring in the headlight bucket. In the headlight bucket there is a plug that has seven or 8 wires on it as i already explained. There is no matching plug to plug into it. and i am going to probably have to cut the plug and make taps.

As for the 8 wires....

The orange/white, as you explained that is Hot goes to the kill switch..
Orange/white for the coils and ignitor
Orange/Red goes to the orange/red from the left hand switch according to the diagram ( i
Orange/Green goes to the Orange from the instrument panel
Gray goes to the ignition switch and the instrument panel.
Yellow/white from harness goes to yellow/white from left hand switch

That leaves the Light green/White which is supposed to go to Green/white for the stator and so i dont know what to do with the wire for that...why is it in the headlight bucket?

Also there is the White/red wire, which you explained, and it is supposed to go to the R/R. ..what do i do with that in the headlight bucket if its one of the wires on the plug?

Also according to the diagram, and I am pretty sure what i saw this morning, the three wires for the stator are Yellow, Green/white, and White/Blue.

I think just those last two wires are my only problems.. of course i will know tomorrow. I will take a picture of the plug in the headlight bucket. The previous owner,,i dont know what the heck he was trying to do.

thanks again, i really appreciate it, if you ever come down to New Orleans, i buy you a bowl of Gumbo. Appreciate all your help.

[timbaux]

Today i got a little more done, got the orante/whites properly paired, but still have five more wires to go... as you see in the picture. The white/red that goes to the R/R why is it in the headlight bucket..same with the green/white..which goes to the stator..

There is an orange/red, orange/green, and gray also coming from the main wiring harness. I brought the bike out into the sunlight so i could see better and could not find anything that could be tied to those five wires. 82 suzuki headligh bucket wiring.JPG

[timbaux]

well.... after looking around, i find yet another diagram that is probably what Steve is looking at, its different than the one i have;

The gray ties into the orange/red and the white/red ties into the green/white...if that is right.. i got one more wire... an orange/green... and i have to figure out where that goes

[Steve]

... i got one more wire... an orange/green... and i have to figure out where that goes

In stock configuration, the Orange/Green (o/g) wire runs from the SIGNALS fuse to power the warning devices on the bike. Those include the turn signals, horn, brake lights and the warning lights on the dash.

.

[cowboyup3371]

FYI, you can get new terminals and connectors from either www.vintageconnections.com or Cycle-Recycle II (http://newmotorcycleparts.net/) that will be a lot better and provide you more room in the bucket than those wire nuts. Vintage Connections also sells the crimping tool

[timbaux]

Thanks! Those wire nuts... i an an electrical contractor i was just paIring thr wires off so i could test them. Those connectirs that are in the website are exactly like the original! Nice!