82 850GL Resto...here we go

[Good Times]

Spent some time soldering my connections tonight. Got to show my son what soldering is. He was pretty fascinated.

Got everything sorted for these connections.


Then I took a look at my solenoid and decided to replace the yellow/green wire and connector.

Started here:



Got the new wire soldered on and then the craziest thing happened. I looked over and sitting there all lonely was the polishing wheel, just calling out to me.


I had to get the panel ready for the new PC-8 that should be on the way.

[SVSooke]

You got to watch those wheels,they grab stuff

[Sci85]

Great work GT. I'm so glad you are going first with the wiring harness so I can learn from following along.

[Good Times]

Great work GT. I'm so glad you are going first with the wiring harness so I can learn from following along.

Thanks Sci.

I'll be the first to say that it is a daunting task when you see all of those wires. I like diving in to stuff like that though. I want to know what makes everything tick, so what better way than to do a spinal tap on the ol' GS.

I think I'm doing it right. Or at least my version of "right." LOL But then again, I won't know until it has been down the road more than a few times.

[GateKeeper]

Way to go GT, it's one thing I did not want to do on my bike, and saw it really didn't need it, all was good, pliable, no hard spots, connections all seemed fine, cleaned it all up, a dab of di-electric grease for each connection, and some new electrical tape over the whole thing, made it at least look like new.....

You will at least get another 30 years out of that harness.....and your work looks to be of very good quality....

[Good Times]

Thanks GK. I thought mine was going to be in worse shape than it is. I was anticipating building a new one. SO glad that's not the case. I could have done it, but it would have taken me a while. I don't have too many wires that need replacing.

I am replacing the positive (red) circuit and the will probably go up a size in wire for the ground circuit (black/white) as well, while adding some new grounds.

We shall see....

[Good Times]

Spent my time today on the bike working with the wiring harness some more. Finished up three of the connectors by soldering the crimps and putting heat shrink on each wire. I rewired the power (red) wire in the harness. In order to do that I had to recreate the crimped splice in the wire. I have been looking for the crimp but can't find them anywhere. Not even vintage connections. I made an order for wire in the stock colors today from RIWS. They are one of the links on vintageconnections.com. I called and talked to them and they told me that they didn't have the crimp and that they just wrapped the wire, soldered it and put some heat shrink over it.... They do reproduction harnesses for antique Rolls Royce and the like. That's almost up to snuff for my '82 Suzuki right? So this is what I did:

The original on the left and the new wire on the right:


And the finished product after solder and heat shrink:


I also found out that my burned stator wires, melted ignition switch connector and non-working running lights were all related to an incorrect wiring job at the starter switch connecting block.

Here's the culprit:


I took this picture the first time I ever looked at any of the wiring about a week or so after I bought the bike. I knew it didn't look right. Now after looking carefully at the wiring diagram, whoever did this had the stator loop wired to the wrong leads and some other crazy stuff going on. Thus the burned circuits.

It's good to figure a wiring problem out. After I get my new wire I will have it fixed up right.

[JimmyR]

Wow - great stuff. I ended up redoing the whole harness on mine - partly because the original was in such a mess and partly because I thought it just be easier to work everything out if I started from scratch - then you don't have to check everything the last guy did.

Good to see solder on those wires too. It seems that the solder took to the wires ok - sometimes the old wire doesn't like being soldered - another reason to start again.

As far as grounding, I used a star ground under the seat and another inside the headlight. Both are connected to the ground point at the rear of the engine. It made grounding a lot simpler.

Glad you have a good wife - mine is awesome too! She thinks a bike project on the go all the time is a good thing. I think we both married well!

[Good Times]

Happy Birthday to me....

Parts in the mail:


Tools:


And an awesome card:


Throw in the fact that it's Saturday, I'm with my wife and kids, it's sunny outside and you get one great birthday. Jesus does love me.

[Sci85]

Awesome. Brought a BIG smile to my face Good Times. And yes he does. Thanks for the post.

[GateKeeper]

Happy Birthday.......

[Flyboy]

Happy Bithday GT,



Where did you get the shopping from, I need to get one of those Emblems for the lower triple?
I was under the impression they were listed as discontinued.

[Good Times]

Where did you get the shopping from, I need to get one of those Emblems for the lower triple?

I was under the impression they were listed as discontinued.

Thanks Fellas! I was putting the new intake boots on when I had to take a break to throw some steaks on the grill. Steak potato and salad. My favorite meal. Steaks on the grill while I work on my motorcycle. I'm pretty sure my life if awesome.

Flyboy I get my stuff from Dillon Brothers if I can't find it locally.

http://www.powersportspro.com/

They do me right. Sometimes it takes a little while to get my stuff, but they have great prices and this last order I emailed Martin (internet sales manager) and he made sure I had it by today. Good people. Have no idea how they do with international.

[pete]

Happy birthday GT!!!

[Good Times]

One more picture blast and then it's off for Spring Break:

Time for these to go:


Out with the old and in with the new:


Think that o-ring is bad?


That's more like it:


Ahhhh....she'll be breathing easy now:




Happy Easter Everyone!!