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That "mysterious" electrical system (Read 1015 times)
Savage_Greg
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Re: That "mysterious" electrical system
Reply #15 - 11/03/04 at 15:42:00
 
rkutzner wrote on 12/31/69 at 16:00:11:
My S40 Factory Service Manual is on order.  If it is ANYTHING like my Z400 manual, you will find it a TON more complete than any Clymer or Chilton type could ever be (in the last 20 years I have used them, they have usually left me wanting more information during a project).  And the pictures in my Z400 FSM are INCREDIBLE.  I found it a non issue to tear the top of my engine apart and put in a high compression piston and intake cam in my Z cause the manual was so complete.  

Same goes for my 2001 Jeep Service manual and 1992 Ford Mustang FSM, no Chilton or Clymer can touch them.

As ALWAYS, you get what you pay for, get the FSM !!!  ....and a good torque wrench, always torque everything to spec.


Your exactly right...for people like you and I.  I do plan to "pop the top" on 2 Savages this winter....

But that is what I try to explain to people because most riders only want to know how to do their own maintenance, but not their own overhauls.  They would like to understand the engine better, but have no intention of putting a micrometer on their conrod journal.  I understand that, and so I tend to try to dissuade them from the SSM at it's higher price and consider the Clymer instead.

That way they won't blame me for money spent incorrectly.  Then if they decide that the need to know more, they also know their options.  Besides, I understand that Clymer recently updated their manual, so it might even be better.
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Savage_Greg
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Re: That "mysterious" electrical system
Reply #16 - 12/11/05 at 07:34:29
 
 
Yep, wiring harnesses can be a head scratcher, but the best tool is just a simple digital multimeter. †That combined with a little bit of basic DC theory, and it can be figured out. †At least for testing a component like a switch or bulb.

I guess the challenge is for something like a rectifier, because then you need a schematic since it is actually a "source" of power. †Without one, those harnesses are a real pain because wires go in, and you have to know where they "come out".
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« Last Edit: 07/12/12 at 21:15:07 by Oldfeller--FSO »  


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Re: That "mysterious" electrical system
Reply #17 - 08/18/17 at 20:44:38
 
Hello I'm new here could someone email me that savage wire diagram above the page please to omar_derr@hotmail.com
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verslagen1
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Re: That "mysterious" electrical system
Reply #18 - 08/18/17 at 22:01:57
 
there's 1 available currently, the rest are being held hostage.

http://suzukisavage.com/cgi-bin/YaBB.pl?num=1294779818
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Re: That "mysterious" electrical system
Reply #19 - 09/17/17 at 10:01:47
 
Hi Greg,
This is what I am facex with, and figure if's my first step to get this baby running again.  Thanks for the diagrams, they will definitely be a help!  For more info on this bike read the introduction for Sad Savage.  Any recommendations on where to start or what not to do will be greatly appreciated!  Thanks in advance.
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Re: That "mysterious" electrical system
Reply #20 - 04/24/22 at 06:02:17
 
Savage_Greg wrote on 11/01/04 at 06:07:44:
And in a "real time" photo, it looks like this... Roll Eyes

I left the regulator on the fender...

http://suzukisavage.com/images/uploaded/harness01web.jpg

According to your photo, looks like I'm missing this Decomp controller which is dead center in the middle of you harness picture, little black box connected to the white connector. I tried zooming in but not sure how many wires and their color.
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Re: That "mysterious" electrical system
Reply #21 - 11/12/23 at 17:44:35
 
Hi Greg.  Awesome job detailing and describing everything.  I'm waiting for my Clymer's manual, but I think you've got it beat with your photos.  I sold my manual when I sold my last S40 and wish I didn't.  While I wait, I have a question.  

My 2005 S40 is leaking oil from where the wires come out of the case from the stator/magneto.  Does that space normally have oil in it?  I remember when I opened the timing plug to do a valve lash and I seam to remember a little oil.

I'm trying to solve my oil leak where the wires come out.  Can I just replace the "plug or grommet" or whatever, or is my leak coming from more internal?  Thanks in advance if you get this!  I see this topic is almost 20 years old.  I'm probably supposed to put this in "rubber side down".
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Re: That "mysterious" electrical system
Reply #22 - 11/12/23 at 18:21:16
 
ThumperPaul wrote on 11/12/23 at 17:44:35:
My 2005 S40 is leaking oil from where the wires come out of the case from the stator/magneto. †Does that space normally have oil in it? †I remember when I opened the timing plug to do a valve lash and I seam to remember a little oil.

yes, there's oil usually up to the hole while on the kickstand.
Quote:
I'm trying to solve my oil leak where the wires come out. †Can I just replace the "plug or grommet" or whatever, or is my leak coming from more internal?

the plug/grommet is molded or the wires are passed thru before the connectors are attached.
usually the wires are pretty tight and don't leak there.
you probably have to pull the cover and apply rtv on the plug.
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Re: That "mysterious" electrical system
Reply #23 - 11/12/23 at 18:57:34
 
Thank Greg.  The prior owner tried to bandage it with some kind of silicon or  rtv.  It failed.  I didnít think there was that much oil passing through that area with the stator and magneto.  It seems like the stator would drown.  Iíll probably end up pulling off the cover and exploring.  Thanks again!  Appreciate your time to reply!
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Re: That "mysterious" electrical system
Reply #24 - 11/13/23 at 19:21:53
 
Some of the aftermarket stators have some sort of funky insulation that splits easy and doesn't like any sort of sealant. †I suspect its Teflon. †Once the insulation splits, oil runs through the stranded conductor and leaks like crazy. †I haven't figured out how to fix it. †One of these days I'm gonna mess around with it and see if I can replace the wires without wrecking the stator.

This one only had about 4K miles when it bit the dust. †:'( †
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Re: That "mysterious" electrical system
Reply #25 - 11/14/23 at 06:46:08
 
Great pic and description, Mike!  Thanks.  Mine is a mess.  After cleaning up in the area, it appears my leak is at the bottom from the generator gasket.  That said, my stator wires have a big wad of silicone or rtv doped up in there.

I think whatís really puzzling me is the volume of oil behind the generator case.  I thought that was a relatively dry area.
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Re: That "mysterious" electrical system
Reply #26 - 11/14/23 at 08:30:54
 
the starter also has a drain hole above the pulley.
anything that drips on the starter will drain there.
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Re: That "mysterious" electrical system
Reply #27 - 11/14/23 at 12:40:30
 
verslagen1 wrote on 11/14/23 at 08:30:54:
the starter also has a drain hole above the pulley.
anything that drips on the starter will drain there.


Anything the drips ďon the starterĒ.   The bike recently had the starter replaced.  Is it possible that if incorrectly installed, it would cause a larger volume of oil in there?  The oil drip has virtually stopped now that the bike has just been sitting and not running.
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Re: That "mysterious" electrical system
Reply #28 - 11/14/23 at 15:18:19
 
och wrote on 10/18/22 at 18:28:57:
Just installed a 35mm ID x 3.5mm thick x 42mm OD o-ring. Fit very snug, had to tap the starter in with a hammer, I'm sure it won't let any oil through. Will ride the bike in the next few days and update this.

This is McMaster part number 1302N604. They are sold in packs of 25 pieces, so if anyone runs into the same trouble, let me know, I'll mail you an o-ring. I have 24 pieces left. †Grin

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Re: That "mysterious" electrical system
Reply #29 - 11/14/23 at 15:37:12
 
Starter possibly missing o-ring?  Hmmm.  Thanks for the pointer.
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