Hey all!

I just succesfully rewired my 1997savage.  As such, I thought I would post the wiring diagram I used.  However, I would like to point out that there are 2 different types of rectifiers.  Older bikes, maybe up to 1995 (??? I'm not sure when they changed) have rectifiers with 6 leads, and newer ones (at least 1997) have 5 wires only.  The difference is that the 6th wire in the old style rectifiers is internally shorted to the red wire in the newer ones.  The service manual wiring diagrams, both the Suzuki and the Clymer, as of 2002, show the rectifiers as having 6 wires.  As such, I have posted two wiring diagrams...

6 wire:


5 wire:


If you use a 3 position SPDT switch (3rd postion (i.e. middle) = off, open) for the Hi/Lo switch, you do not need the headlight relay that is on newer models.  My switch is rated at 6A.

Also, the two stock fuses are 20A, and I added a 7A fuse in the headlight circuit, and a 3A fuse in the tail light circuit.

My ignition switch is a 5A SPST momentary push button.

I would recomend 18 gauge wire as a minimum size for the lighting circuits, but I have my rectifier and similar items at 16 gauge wire, except for the big fat wires that go to the battery, starter relay, and starter motor.

The wiring harness I now have has only the following items:
Hi/Lo/off -> headlight
tail light & rear brake (pedal) light switch & light
rectifier
battery
decomp controller & decomp solenoid
ignitor
starter motor
starter relay
ignition coil
magneto & pickup coil
ignition switch (key)
starter switch


It does not have:
turn signals, switch, relay
side stand switch, side stand relay, side stand diode(s)
clutch interlock
neutral switch (actually, it's still in the case, but disconnected)
anything going to the speedo
horn & switch
about 1800 feet of wire
front brake light switch (the one on the hand lever)
that's all that comes to mind

European models note:  some non US models may also have thottle position sensors.  I have no clue about those and you'll have to work that out for yourself...

Do California models have any extra wiring (for emissions purposes)?

I'd also like to point out that there may be some other differences in the older, 1986,87 models, specifically in the decomp contoller, ignitor, and sidestand interlock circuits.  I am not sure how they would affect the above diagrams.  Prolly not at all is my GUESS.

1997 Ignitor

1: Black/Yellow tracer   -> ignition coil;
2: Black,  no tracer  -> starter relay
3: no wire
4: no wire
5: Orange/White tracer -> ignition coil & kill/start switch = + 12V
6: Green,     no tracer   -> magneto pickup coil
7: Orange,   no tracer   -> magneto pickup coil
8: Black/White tracer    -> ground



see this thread also for older ignitors.

and I just found thisin our own tech sect...  

Quote:


It seems like the '78 SR500 I had did have a manual mechanism for the startup.  It is easy enough, just pull and hit the starter and as soon as it turns and get the first fire let it go.  It has been a while but it is simple to do with a few tries.

vroom1776 wrote on 12/31/69 at 16:00:06:

Doesn't the key pull out in the park position?

Sure would suck to loose the key.

I am gonna try this, but will need to figure out which wires from the ignition switch go to what... I will do some playin this week and will let everyone know how it goes!

vroom1776 wrote on 06/04/07 at 15:20:36:

not gonna work it seems. You need +12 on the CDI whilst cranking. Stock key switch provides +12 on EITHER one contact OR another. Crank or spark. Should work out some solution with diodes to use stock switch.

Does anyone have the diagrams ?
The third party photobucket is annoying .
Especially when you need a technical pic like a wiring diagram.
Thank You

Hi Andemon.  Here's a simplified wiring diagram I've started for the bobber we're doing.  It's not complete, but it's a start.

Lemme know if it helps.