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Message started by mikelhsr1982 on 06/09/10 at 03:11:09

Title: Tough Decision
Post by mikelhsr1982 on 06/09/10 at 03:11:09

Im facing a tuff choice here. Im at my breaking point with my bike and its wiring system. Ive pondered the notion of selling it whole, or as parts. But here is the ultimatum. I looked on the pinwall cycle ebay store and the have the original harness for around $30. If I buy this and hook it up will I still be able to bypass the decomp system and the clutch/sidestand safety system?

Title: Re: Tough Decision
Post by Stimpy on 06/09/10 at 03:33:17

I've bought parts from pinwall before, great company, no issues.

$30 is a minor investment and the total install / test time
should not take more than one afternoon, I would give it a shot.

Sell it for parts? bad idea. Trust me, better try selling it whole to 1 buyer.

...Have you identified already what the problem component is?
The ls650's electrical system is actually pretty darn basic.

Both the side-stand and clutch safety switches can be disabled
in 5 minutes with wire some cutters and electrical tape, are
these what are giving you all the trouble? Good luck.

Title: Re: Tough Decision
Post by mikelhsr1982 on 06/09/10 at 04:26:41

Well, its a hairy story. I got the bike in a trade and the only fought was the starter. Before it went out, I had it cranked over. The wiring was bird nested real bad, and instead of a 6 wire rectifire, it has a newer 5 wire one. after the bobber make over, I tried to follow the bobber diagrams on here and have no luck what so ever. My key switch wiring also differs from the diagrams. One diagram says there is red,orange brown and grey. Mine has two orange, big and small, red and brown. I was thinking of getting a new ignition switch from lowbrow customs for like $15 or so. But that is the breakdown of things. Thanks for the reply, I could use any help I can get.

Title: Re: Tough Decision
Post by mikelhsr1982 on 06/09/10 at 04:29:05

31160B0F121B620 wrote:

I also see your in Germany, I used to be stationed in Mannheim. I loved it there and absolutely miss it.

Title: Re: Tough Decision
Post by Stimpy on 06/09/10 at 05:29:45

Yup, maybe 90% of all motorcycle problems have to do
with bad/old/rusty wiring and/or electrical components.

$30 for a "new" electrical system is a steal and well worth it.
The ls650 is a great bike and there are plenty of nearly 30 year
old savages on the road today running with no issues at all.

* And about myself I'm kinda close to spangdahlem but I'm not
with the military, and yes, it's actually pretty nice here, kinda
looks like wisconsin and/or pennsylvania, take a look at this
video I recently posted over at the cafe section and, good luck
with that wiring!

http://suzukisavage.com/cgi-bin/YaBB.pl?num=1273930771

Title: Re: Tough Decision
Post by mikelhsr1982 on 06/09/10 at 06:46:57

Hey thanks a lot Stimpy. Now I miss it even more.lol. Out of all the places I seen in Europe, I liked Garmisch the best. Thanks again with the wiring. I think I'm gonna get the harness and start fresh.

Title: Re: Tough Decision
Post by james may on 06/09/10 at 07:22:19

yeah good idea on the new harness.. for 30$ ya can't go wrong.. it'd probably take close to 30$ worth of wire to build your own harness from scratch.. I could do it too(worked on electric power industrial equipment for 4 years and am an engineer), but I'd opt for the new harness myself if in a similar situation..

Title: Re: Tough Decision
Post by Tanker2Biker on 06/09/10 at 10:53:13

31160B0F121B620 wrote:

I also see your in Germany, I used to be stationed in Mannheim. I loved it there and absolutely miss it.

Spent 3 years in the old FRG back in the 70's, North of Frankfurt and really enjoyed it. Course, I was a "little" younger and smaller then. ;)

Title: Re: Tough Decision
Post by dasch on 06/09/10 at 11:08:59

Mike, if you have time, sit over the schematics with a hiliter and you will figure it out in 30mins tops. It's not so hard. 5 wire reg/rec makes it even easier. $30 is indeed cheap, but where's the spirit, man?? Whatever you decide - good luck with it.

Title: Re: Tough Decision
Post by T Mack 1 - FSO on 06/09/10 at 13:23:53

Mike,
When I compared the wiring diagrams in the Cylmer manual to the Factory Serive manual, I thought the Factory one was easier to trace the wires. If you pick up a newer one covering though 2006 or so, they have the wiring diagrams all the way back to 86. That's real handy when comparing the diffferences. And if you're morphing things together, it's a must have.

T. Mack

Title: Re: Tough Decision
Post by mikelhsr1982 on 06/09/10 at 14:23:18

767361717A120 wrote:

I think the highlighter is what I was looking for while doing it the first 3 times, lol. So having a 5 wire on an 87 wont be so bad.

Title: Re: Tough Decision
Post by mikelhsr1982 on 06/09/10 at 14:24:43

5F26466A68603A0B0 wrote:

I downloaded a clymer for free somewere on the net, not sure were I got it now. Can a factory service manual be downloaded to.

Title: Re: Tough Decision
Post by Chief Gunner on 06/09/10 at 15:01:06

Make sure you get the right model year harness. The CDI connectors change.
Not sure about the decomp solenoid, but the kickstand and clutch connector you can cut back to the harness where you can hide it and just solder or tie the two ends together to complete the circuit.

What year harness are you removing? I need a connector that will work on a 97 CDI box to splice into my existing harness.

Title: Re: Tough Decision
Post by mikelhsr1982 on 06/09/10 at 15:13:32

474C4D414243514A4A4156240 wrote:

I dont know if I would call it a harness. What I have is the connectors and a dissected harness. Its in about 100 pieces. Its an 87. I have the original connectors to the main components. Pinwall cycles may have the 97 harness to get the connector.

Title: Re: Tough Decision
Post by Chief Gunner on 06/09/10 at 17:51:39

rgr, Got an 87 at home myself. When I get back I'm looking at putting an engine from a 97 in it, I've got the CDI box for the 97, just got to get the connector and splice it in. I've got plenty of time though.
I've got a bad head in the 87, but I haven't had a chance to look inside the 97 engine. If it's in better shape all around I'll just swap motors. If not I'll just swap the head and I won't have to worry about the connectors.

Good luck with your wiring man.

Title: Re: Tough Decision
Post by mikelhsr1982 on 06/09/10 at 18:32:17

Thanks man, I need it,

Title: Re: Tough Decision
Post by mikelhsr1982 on 06/09/10 at 20:42:23

Does anyone know if it would be possible to use an aftermarket key switch instead of the stock one on my savage. I really dont like the stock one, and cant ever seem to get the wiring right on it. The book tells me its supposed to be red,grey,brown,and orange. I have two oranges,red,and brown.

Title: Re: Tough Decision
Post by Charon on 06/09/10 at 22:14:14

Just remember that whenever you download a manual for free from the Internet, you are cheating somebody out of his royalties. The people who write those manuals put a good bit of work into them, and deserve to be paid.

Title: Re: Tough Decision
Post by jef.savage on 06/11/10 at 06:13:45

+1 what Charon said. I downloaded the Clymer's and then bought a hard copy. It's very convenient to have both.

Clymer's shows two oranges a grey and brown for 86-95 and no reds anywhere ever except the positive battery connector. So I'd try red = grey. When I dealt with this on my bike and had two oranges they were usually slightly different and I could get a hint which was which. I also used the diagrams with a multi-tester to trace wires I was unsure about. When it starts making you nuts just walk away. Often it looks a lot different the next day, or week.

I don't see any reason you couldn't use another switch but you'd still need to wire it.

Title: Re: Tough Decision
Post by T Mack 1 - FSO on 06/11/10 at 11:38:59

5054565851554E4F0C04050F3D0 wrote:

- Orange is switched power (output of the switch)( note: orange is switched power everywhere on the bike, but some wires have a extra stripe on them)
- red is unswitched power. I forget if it comes from the battery or from the fuse block. Don't have schematic in from of me.
- brown goes to the rear running light. It's at the key switch for the "Park" setting which I was told is an European requirement. Haveing the park setting, not the brown wire at the switch....

Never saw a free FSM to download. But you can get them on ebay used. If doing work inside the engine, the FSM seemed slightly better.