complicated..

[dane_lindsay]

the wiring harness and engine for a 2002. frame and (formerly) handle controls from a '96. purchased 2004 handle controls, as they looked exactly like the 2002, but, HA the connections could not be more different.

[starwalt]

The good news is the electrons don't care what year the harness is as long as they get where they want to go.

The bad news...how did you start down this path anyway? Sounds like a Heinz mix for sure...only not 57 varieties of GS500's.

Do you have a Haynes manual? It has pretty color wiring drawings of all the GS up to 2002. The real issue here is connectors it seems. You may be able to find the correct connectors to mate up with the 2004 controls via ebay or the want/ad forum here.

Man, it sounds like a mess. What year are you trying to make or is this a "custom" conglomeration?

I certainly would not wear mascara in your part of Georgia!  

[Ed89]

Get off that bridge now!!!    It will all work out!!!

That was some funny s***, Dane.   :lol:  :lol:  :lol:

Cheers,
e.

[pantablo]

... i even bought mascara.
   help save a young man's dignity, tell me it's ok, that it will all work out...

YOU'RE DOOMED.

















j/k.

[dane_lindsay]

its still the same turn signal,headlight, starter, kill switch set up, so 2004 and 2002 should work together, but they sure dont.

right now i have laid out my 96' alongside my '02  harness, so as to try and have some idea of what i am up against. i also have the '04 switches and '96 switches here. it goes something like this...

Code Select Expand

2004 left (choke/turn/headlight/horn):  main connector=yellow 3x3 pin.
                                       small connector=yellow 2 pin

     main looks like black             blue          green
                     black/white       yellow        white
                     blue/black        (empty)       yellow/white

     small yellow looks like    yellow/black    yellow/black

     in addition, two small leads(b/w) exit the switch and go only 3 inches
     (clutch safety switch leads, i believe)


1996 left (same functions):  main=yellow 3x3
     (interestingly, this is the male for the female counterpart on the 04,
     they would fit each other perfectly)

                     black           blue            green
                     black/white     yellow          white
                     blue/black      (empty)         (empty)

     in addition, a yellow/white wire with a bullet connector exits at the
     headlight end of things. as you can see, the 04 and 96 are almost
     identical, save for the small yellow 2-lead connector, leads exiting the
     housing (for clutch safety?) , and the connector choice.


          ------------------------------------------------------


1996 wiring harness yellow plug(left switch)  3/3 wire
                      green          blue            black
                      white          yellow          black/white
                      (empty)        orange          black/blue


2002 wiring harness yellow plug(left switch)  3x5 wire

                      black           blue           green
                      (empty)         blue/black     black/white
                      (empty          yellow         orange
                      (empty)         white          yellow/white
                      (empty)         yellow/green   black/yellow

     the black/white wire exits the connector and runs directly(an inch off)
     into a strange clear 6-pin thing, with 5 other black/white wires bridged
     together and coverd with a plastic shield where the female plug would
     go. my '96 has no similar component.


          ------------------------------------------------------


2004 right(starter/kill)     black 2x3
                       black/yellow     blue/black        red/black
                       orange/white     (empty)           orange/blue

     in addition, a 2-pin exits the housing and terminates at 3 inches:
                       red/black        blue/black

     apparently these would connect to brake light switch at master
     cylinder.


1996 right (starter/kill)     black 2x3  (perfect male for 2004 female)
                       black            yellow/white      yellow/white
                       black            orange/blue       orange/white

     the 2 black wires exit before the housing, terminating at 3 inches.
     again, i assume these are for the brake light.

     the yellow/white wires exit the connector in the housing, and
     terminate at 2 inches into one female bullet connector, which
     apperantly connects to the yellow/white bullet male from the left
     switch. a yellow/green wire from the right switch exits in the housing
     and becomes a female bullet. this never attaches to the 6-pin, it runs
     independently. this female bullet attaches to a male yellow/green
     coming from the harness.


          ------------------------------------------------------


1996 wiring harness plug (right switch)  black 2x6
                         
         grey              orange            orange
         orange/white      orange/blue       black/white


2002 wiring harness plug (right switch)  black 2x5
 
         orange      orange        (empty)         grey           black/white
         orange      orange/blue   orange/white    black/yellow   yellow/white

[dane_lindsay]

so ...

[Kerry]

i forgot that it gets reformatted after posting.

There - is that any better?  :dunno:

I thought about actually colorizing the text, but that would have taken a good while....  

[dane_lindsay]

THANKS KERRY! you are truly the proverbial "man". now all i have to do is find a way to make some strangers with knowledge and some free time give a damn.. a six pack of highlife or something? could i wash your bike?

[Kerry]

About the "choke/turn/headlight/horn" units.  You said:

as you can see, the 04 and 96 are almost identical, save for the small yellow 2-lead connector, leads exiting the housing (for clutch safety?) , and the connector choice.

Are you talking about this area?

If so, then you are right about them being for the clutch safety interlock.  If you don't mind not having the safety feature you could just connect the wire ends togther, right?

[davipu]

how about gas money and a couch to sleep on, and I'll play mobile mechanic.

[Kerry]

Make sure you agree on a dollar amount for gas up front, or davipu might do a "Four Corners" tour on your tab!

Just Kidding.... :mrgreen:

[davipu]

what's a side trip to maine on the inbound leg and a side trip to cali on the outbound leg? :dunno:  not that the thought crossed my mind or anything....    na, I whould only ask for gas money from here to there which is like 2500 miles each way( which is about 50 gallons of fuel at about 2 a gallon avarage price for each leg)  and my sister is always down with me hanging out in san diego and will give me gas money to come down and babysit,  that's 1100 miles each way, so I basicly have fuel costs covered for going across and back and up and down. and I get to hang out some gstwiners, and spend some time with my family on the trip.   oh no, I have leaked my evil plan for a cheep four corners tour. :mrgreen:

[John Bates]

That was a great write-up of wire/connector stuff.  Looks like there are three electrical designs for the GS.  1996, 2002 and 2004.

Are schematic/wiring diagrams available for all these? :dunno:
You'll need copies of all three to match up wires to controls and then find compatable connectors. Maybe you could find a 2004 harness on eBay for the connectors to match the 2004 controls.
:dunno:

[Blueknyt]

continuity tester, test light, crimp connectors, Notebook, instant polaroid, electrical tape,couple 2 liters of mountain Dew, and some calming music in background. from there trace,test, take notes with photo, cut, crimp, tape.

[dane_lindsay]

davipu, thanks for the generous offer, if serious, but for the cost, well..i did think about the 2004 harness, some 2004 parts are up on ebay, but because the 04 ignition primary on 04 is 6-point, and all earlier are 2-point, i think there may be some problems, and the CDI is different as well.