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Message started by strang on 08/30/15 at 14:39:22

Title: fuse block Wiring Diagram
Post by strang on 08/30/15 at 14:39:22

I am thinking of rewiring around a central fuse block. I have used it on another bike with success (xs650) but I'm a bit stuck as to how the ignitor will work on the Savage. The "Simplified/Chopper Wiring Diagram" runs a diagram with a 2 wire ignitor but the factory wiring diagram shows a 6 wire? What's the 2 wire ignitor about? Or how do I wire in the 6 wire ignitor to the this diagram? (wire colours are just mock up, obviously)

Title: Re: fuse block Wiring Diagram
Post by Serowbot on 08/30/15 at 14:50:25

We have a fuse block?... :-/...

Title: Re: fuse block Wiring Diagram
Post by verslagen1 on 08/30/15 at 15:02:52

Are you disabling the decomp solenoid?
If yes, then four wires will do ya.

Title: Re: fuse block Wiring Diagram
Post by Tiki on 08/30/15 at 15:03:02

Quick question:

What is the name of this part and is it waterproof?
http://i59.tinypic.com/2mgqxx4.jpg

I want to relocate stuff and rewire my entire harness to clean everything up ::)

Title: Re: fuse block Wiring Diagram
Post by verslagen1 on 08/30/15 at 15:39:09

rectifier, yes, connector, no.

Title: Re: fuse block Wiring Diagram
Post by HovisPresley on 08/30/15 at 15:40:00

That's the regulator/rectifier.

Title: Re: fuse block Wiring Diagram
Post by strang on 08/30/15 at 15:44:50

Hovis: regulator and the unit itself (grey/black thing) is pretty much waterproof ie. you don't have to stick it completely hidden away under the seat. New triumphs run it on the front of the bike even.
Vers: Yes have sorted out manual decomp.
So, down to 4 wires, my diagram has 2 coming off - how do I square the circle?

Title: Re: fuse block Wiring Diagram
Post by verslagen1 on 08/30/15 at 15:57:19

565157444B42250 wrote:

So, down to 4 wires, my diagram has 2 coming off - how do I square the circle?

correction, your diagram has 3 wires coming off.
The 4th wire is from the starter to retard timing.

Title: Re: fuse block Wiring Diagram
Post by strang on 08/31/15 at 03:19:53

yes sorry 3 wires.
deleted non essential wires?:

Title: Re: fuse block Wiring Diagram
Post by strang on 08/31/15 at 03:20:33

into fuse block diagram

Title: Re: fuse block Wiring Diagram
Post by verslagen1 on 08/31/15 at 07:25:09

I'm not sure if those "extra" wires need to be tied up or down.
I would check their function before deleting them.

Title: Re: fuse block Wiring Diagram
Post by strang on 08/31/15 at 11:00:44

Safer to do this?

I got my colours mixed up previously, my eyes are not the best.

Title: Re: fuse block Wiring Diagram
Post by verslagen1 on 08/31/15 at 11:37:05

Just checked another wiring diagram... those 2 wires are important.
So you need all 6 wires.

http://www.savageriders.com/verslagen/Circuits/96-04-ig-starter.JPG

Title: Re: fuse block Wiring Diagram
Post by strang on 08/31/15 at 11:46:28

what's the "pickup coil"?

Having re-read all the tech docs this is the most informative:

1997 Ignitor

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

Wish "vroom1776" was still around as he seems to have cracked it at some point.

Title: Re: fuse block Wiring Diagram
Post by verslagen1 on 08/31/15 at 11:59:12

787F796A656C0B0 wrote:

what's the "pickup coil"?

That thing that tells your sparkplug to go "spitz"

Title: Re: fuse block Wiring Diagram
Post by strang on 08/31/15 at 12:08:25

I know the ignition coil obviously but sorry still don't know what part is the "pickup coil" or "crank sensor". I'll have another look at my bike tomorrow and look for the green and orange wires. ;)

Title: Re: fuse block Wiring Diagram
Post by verslagen1 on 08/31/15 at 12:21:36

It's the electronic equivalent of points.

Title: Re: fuse block Wiring Diagram
Post by strang on 09/01/15 at 08:07:32

Had a look at my bike and the wires going from the CDI to the "pickup coil" are headed to the alternator/stator. I presume it's incorporated.
Today I was still having problems with gremlins in my stock wiring loom so am going to rip it out and try this diagram.
Wish me luck. Will document.

Title: Re: fuse block Wiring Diagram
Post by strang on 09/01/15 at 13:46:14

If someone with the knowledge could once this over then that would be most helpful as I am gonna start wiring it up in the morning.

Title: Re: fuse block Wiring Diagram
Post by strang on 09/02/15 at 03:26:24

from http://www.ls650.eu/community/

Title: Re: fuse block Wiring Diagram
Post by strang on 09/02/15 at 13:56:07

Stripped down the stock harness today; removed all that tightly wrapped electrical tape. Took quite a long time - fook me, how sticky is that shite?
Found a ton of connections sitting under there, multiple earths and whatnot, just crimped together. Quite prone to gremlins if your loom has been off the bike for a bit. Not too impressed with Suzuki's workmanship having seen what's under all that gooey tape. :o

Title: Re: fuse block Wiring Diagram
Post by strang on 09/13/15 at 12:55:56

left side switches

Title: Re: fuse block Wiring Diagram
Post by strang on 09/13/15 at 12:57:21

right side switches - starter/headlight cut-out switch is pretty clever.

Title: Re: fuse block Wiring Diagram
Post by verslagen1 on 09/13/15 at 22:59:20

I've looked over your diagram and made a few changes.

Edit: I checked it again and found an error with the stater relay and uploaded a new sketch.

Title: Re: fuse block Wiring Diagram
Post by strang on 09/14/15 at 05:30:21

thanks verslagen, very helpful.
have amended my previous R and L switch diagrams, had messed up the input/outputs destinations. All good now.

Title: Re: fuse block Wiring Diagram
Post by Arty Dodger on 05/18/24 at 10:23:21

[url][/url]
302334352A2721232877460 wrote:

I've looked over your diagram and made a few changes.

I keep having issues with the wiring on my bike and I've gone through 3 batteries. Something happens and the battery stops registering a multimeter. I followed this diagram to the best of my ability, but I've removed decomp, flashers, and use off/on/start key like a car so I don't have separate kill/start buttons/switches.

I wonder if there is a short somewhere that's shorting out my battery, but I've gone through the wiring (I had to create my own wiring harness) several times and can't figure it out.

My confusions are with the key switch and the aftermarket starter solenoid I have. The starter solenoid has a Battery and Motor terminal and 4 extra spade terminals to hook up. I have my CDI unit connected to it and a ground. The key switch has 3 terminals, off/on/start. What should be connected to them?

I have a couple of questions to start:
1.Has anyone seen a simple chopper diagram with a fuse block?
2. Anything else I should be looking for?
3. I have my wiring in a stainless steel fake oil tank. Could the solenoid touch the ss metal and cause a short that will kill my battery? I have rubber boots over the battery and motor terminals so I dont think that's it.

Any help or advice is greatly appreciated. Having to go through several batteries is killing my bank, but I'm so close to being done.

Title: Re: fuse block Wiring Diagram
Post by verslagen1 on 05/18/24 at 10:58:36

If you can supply the starter switch and relay make and model you got I'll look at it.

Also what fuse box are you using?

Title: Re: fuse block Wiring Diagram
Post by Arty Dodger on 05/18/24 at 11:03:36

Thank you! The solenoid I have is this: https://www.amazon.com/gp/aw/d/B076P1RM7P?psc=1&ref=ppx_pop_mob_b_asin_title

And the fuse block is this: https://www.amazon.com/gp/aw/d/B075L88PCR?psc=1&ref=ppx_pop_mob_b_asin_image

Title: Re: fuse block Wiring Diagram
Post by verslagen1 on 05/18/24 at 11:39:39

I don't see how the relay spade connectors are supposed to be hooked up.
Any diagrams? Addition marking? etc?

Also the what ig switch are you using?

Title: Re: fuse block Wiring Diagram
Post by Arty Dodger on 05/18/24 at 17:23:37

I’m not sure either on the spade terminals. The switch I’m using is this one: https://www.amazon.com/your-orders/pop?ref=ppx_yo2dv_mob_b_pop__np_1_pp&orderId=112-1029784-9596246&lineItemId=rmonovqllnqouny&shipmentId=GkBTzl5YH&packageId=1&asin=B099971JNJ

I have one of them going to ground and the other is going to the igniter. Indicated from this diagram. It does say to connect the igniter wire to the starter motor wire but the igniter wire is 16ga and the starter is 4ga wire.

Title: Re: fuse block Wiring Diagram
Post by verslagen1 on 05/18/24 at 19:18:56

2536303D202B20232136440 wrote:

That's not a good link.

If you had the OEM harness, they connect the igniter to the starter with a ring terminal on the 16ga wire (I think it's smaller) connected to the post of the starter wire.

Title: Re: fuse block Wiring Diagram
Post by Arty Dodger on 05/18/24 at 19:24:29

Oh I see! Yea I didn’t get the oem harness from previous owner. I’ll try that. After of course I buy another battery. 4th times the charm, right?!

I can move the spade to a ring and add it to the post of the starter wire. Do you think the ground is good in the spade terminal part?

Title: Re: fuse block Wiring Diagram
Post by verslagen1 on 05/18/24 at 21:18:27

Since I cannot determine the function of the 4 spade posts, you need to do some checking before connecting to any of them.

Such 1 of the spade connectors maybe common with the motor connector.
And 1 of the spade connectors maybe common with the battery connector.
This would be similar to the configuration of the savage wiring.