Designing anew wiring harness, have some questions

[Guest]

Hello all. I've got a 1982 GS650GLX that I completely tore down and I'm now rebuilding it from the ground up. I've got the mechanicals down (I believe), but now need to build a new wiring harness. I'm starting from scratch because the old wiring harness was pretty near to destroyed, and I tore out the dash and am replacing tach/speedo with a TrailTech Vapor, and am ditching all of the indicator lights, as well as the fuel gauge and gear position indicator.

So, what I'm removing from the harness is:
Turn signal indicator
Neutral indicator
Oil pressure indicator
High beam indicator
Fuel gauge light
Speedo light
Tach light
Fuel gauge sender
Gear position lamp switch
Output terminal
Oil pressure switch
Gear position indicator

What I'm adding is just the Vapor, and its tach/speedo/odo/cylinder head temp gauges all hook up to the unit directly and don't need to be connected to the electrical system. What I'm struggling with is drawing up a new wiring diagram because when I try to base it off of the original one, it seems that everything hooks up to something that will no longer be there, and when I use a generic "simple" one that I find online, it doesn't include things like the horn/turn signals/etc that I need to pass a very strict VT state inspection.

Additionally, I'm wondering what on earth the lighting switch is and where it might be found since I didn't find it when tearing down the bike. If anyone has some info, or could point me to somewhere that does, I would be massively appreciative. Thanks in advance!

[Steve]

Additionally, I'm wondering what on earth the lighting switch is and where it might be found since I didn't find it when tearing down the bike. If anyone has some info, or could point me to somewhere that does, I would be massively appreciative. Thanks in advance!

I'll address your last question first.

The lighting switch is a left-over from previous years. I know the '81 650L had the switch, but it was mechanically blocked so it could not be moved away from the ON position. I believe the switch was removed some time during the '82 production year. Look on your VIN tag. If the production date was before January or February of '82, you might still have a switch, but if it's after that, the switch might be gone. It would have been on the left handgrip, above the turn signal selector and to the right of the High/Low beam selector.

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[trmcgrade]

Great, thank you for that. I'll be sure to have a look at that. I guess my next question would be how to remove something from a wiring diagram, so that I can re draw the diagram without all of the bits and bobs mentioned in my first post.

[Steve]

It's a tedious process, but I have been known to take the diagram, load it into a photo-editing program (I don't have anything any more exotic than MS Paint), then erase the parts that aren't 'needed'.

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[hannibal]

I printed the diagrams and traced wires with colored pencils.

[free99]

Hey everyone, first post here. I used a handy website to draw my redone wiring diagram called "draw.io". I've attached my wiring diagram, all you have to do is go to the site, and drag components like switches, buttons etc onto the stage. Once you arrange 'em as you like, draw lines between them to create "wires".

Double click a wire to add a label. I actually labeled and color coded all my wiring per this in redoing my 450's wiring.

Best of luck, lmk if you have any questions
GS450L Wiring Diagram.jpg

[trmcgrade]

Thank you all for those tips. I'm gonna give the new harness a shot this afternoon and we'll see how it goes