GS 500 ATV conversion wiring help

[yamazuki]

Hello everyone! I'm doing a little conversion, and am getting stumped on the wiring.  I aquired an '89 GS 500 as a complete bike that was used for racing.  It started and rode great, that is until a friend ran into a ditch on it.  The forks were trashed, but the rest of the bike was still in good condition.  Since I can't really own a motorcycle (wifey doesnt like them too much..), I decided it would be a great motor for a four wheeler frame that I have. 

I started the bike up before I removed the motor to confirm that it was still in running condition (it sat up outside for close to 2 years after the crash).  I had a shop modify my ATV frame for me and install the motor, so I gave them all of the parts from the bike.  They were going to complete the bike for me, but problems arose, so after 2 years of them "sitting" on my toy, I decided to get it back and finish it myself.

It is close to being finished now, but I am unsure on all fo the wiring.  All the parts I have are connected to the wiring harness, and mounted.  But since it was a race bike, some wires were left unplugged, some even bastard-ized.  I need some help with the following:

1.  What are the basic electrical parts needed to make the bike operational?  (I'm not going to be needing turn signals, or a kick stand switch, etc.)

2.  I know I'm missing the ignition switch (I'm sure it's in a pile of junk at the shop it was at), can I bypass that easily, or should I just spring for a new/used one?

I know this is a lot to read, so if you got this far, THANK YOU.  And if you can offer any guidance on this, again, THANK YOU!  I can post some pictures of some of the wires that I am unsure of, if would help out any.  Just in case anyone is wondering, the motor is going into a '99 Yamaha Warrior ATV. 

[starwalt]

...1.  What are the basic electrical parts needed to make the bike operational?  (I'm not going to be needing turn signals, or a kick stand switch, etc.)

Assuming the bulk of the hacking was done to make it a track bike [that means the starter circuit has been modified to bypass the neutral switch and side stand relay...etc], the GS engine needs the following:
-> +12V into the wiring harness when "On"
-> Neg into the wiring harness and the large Neg to the bottom of the motor.
-> +12V into the starter relay when the start button is pressed
-> Intact wiring from the wiring harness to the ignition module
-> Intact wiring from the ignition module to the coils.
-> Intact wiring from the signal generator to the wiring harness
-> Intact wiring from the coils to the spark plugs

I know this is a lot to read, so if you got this far, THANK YOU.  And if you can offer any guidance on this, again, THANK YOU!

Tis nothing! If you really feel the need to compensate, I'll give you my Paypal account address. 

[makenzie71]

If you can't figure out what you're got you'd be best off just buying another wiring harness and bypassing the kickstand and nuetral switches.

[scottpA_GS]

PICS !!! Sounds like a cool project... Show us some pics

[yamazuki]

Thanks for the quick replies everyone!

Starwalt - That is exactly what I was looking for!  I found Kerry's wiring diagram, so I printed it out and brought it home.  I'll be honest with you all, I have never actually used a wiring diagram before, so I was a bit worried... I did sit down with it, and slowly, it all came to me.  I checked off everything I found that was connected and present.  I do seem to be missing the Starter Relay and Fuse, and the ignition switch (I am just going to get a replacement for it, no riggig it..)

I have the coils and plug wires, but am not sure which side of the motor is considered Left or Right side.  I would guess the side the shifter is on would be the left...? (Some of you may find this funny, so go ahead and laugh)

There is a plug at the front of the harness that looks like it may have been broken.  It has 2 black/white wires going to one section, 1 white going to another section, and 2 yellows to another section, to make it a 3 prong plug.  Different wires (pretty much just jumper wires) were connected and taped to this plug, but I have no idea what they would be jumping to..  I traced the colors/plug to the Dimmer and Horn switch.  So I think..

I will get some pictures up as soon as I figure out how to post them.  Any quick help with that would be greatful as well.

[that_guy]

and bypassing the kickstand and nuetral switches.

Which I might say is especially easy to do with a simple 1 wire jumper..

[yamazuki]

I'm making sure I have this picture posting thing right.  If it works, then here's a picture (with a little bit of photoshopping) of my wonderful Suzuki that I have had for close to 10 years!  I'll get the GS500 Warrior pics posted as soon as I get home today.

[starwalt]

...I have the coils and plug wires, but am not sure which side of the motor is considered Left or Right side.  I would guess the side the shifter is on would be the left...?

Left side coil wires are White & Org/Wht. Right side coil wires are Blk/Yel & Org/Wht.  Left is as you are on the bike, facing forward...shifter is on left, left cyclinder is same side.

...There is a plug at the front of the harness that looks like it may have been broken.  It has 2 black/white wires going to one section, 1 white going to another section, and 2 yellows to another section, to make it a 3 prong plug.

This is/would have been the headlight connector. There shouldn't be anything jumpered here for track bike. It depends on whether the previous owner was using the head light constant on as a power source though.

[yamazuki]

Thanks for the info on the correct coil side. I'm starting to get a good understanding of what I have and what I need.  I have the ignition switch from the four wheeler, so I think I will tie that into the harness, instead of getting a replacement ignition switch (the stock atv switch mounts in the plastics all nice a pretty).  The only other thing I seem to be missing is the Starter Relay and fuse block (could that have been bypassed for the track??).  I have started looking for a replacement this morning. 

Here is a picture of the headlight plug.  Now that I think about it, I do believe there was a headlight on the bike. [The original owner raced the bike, then started using it as a parts bike.  When it was purchased, it was in pieces.  It was being rebuilt to become street legal, but never got that far.]




Here are a few pictures at different angles.  I know, it looks ugly right now, but once I get all of the plastics on, and the flat tire aired up, it looks pretty sweet.  I'll post more as it comes closer to being "finished"...




Thanks for the help everyone!

[that_guy]

that harness looks to be in decent shape. 

[yamazuki]

The harness is actually in pretty good shape.  They did modify it, but they did it right.  I will get some good pictures of the center of the harness soon.  That is where the bypassing/jumpers are at that I may need some guidance with.

On a different note, I also obtained a Honda NT hawk 650 from the same person, and it was raced as well.  I currently have the motor on a go-cart type frame.  The chain from the motor runs to a small differential, but the gearing is so off, that you can go through all the gears, and not break 10 mph..  It needs a live axle under it.... but for now I'm mostly concerned about the ATV project.

[starwalt]

The only other thing I seem to be missing is the Starter Relay and fuse block (could that have been bypassed for the track??).

I don't know how he would have used anything else (for the trouble), but the starter relay/fuse block for 90+ models is a red and green affair. Look on THIS PAGE at the second and third picture. I apologize for the poor photos. Made those with a 1 Meg pixel camera.

You can also see the red portion in the middle of the partial wiring harness picture at the bottom of the thumbnails page.

That Honda looks like a neat bike. I may have to consider one like that for a future restoration project.

[makenzie71]

yamazuki, you just got an email.

[yamazuki]

Ok, I do remeber the starter relay being on the bike when I tore it down, so I am waiting for a new one to arrive in the mail soon.  Thanks for the link to the pictures Starwalt... I actually checked out your site right after my last post.  Lots of good info, nice site! 

I am getting closer to having it running, thanks to everyone here, and the wiring has become much more clearer to me.  Soon , I will no longer have to make the vroom vroom sounds while sitting on it!   

I do have another question though...  This time it is about the air filters.  The way everything is positioned right now, I only have about 3 inches in between the carbs and the top frame.  There is no room to put any air filters on it (at least no atv filters), and the stock airbox will not work.  I have no intentions at all, of running this thing without any filtration though. 

Any one have any ideas that I could try?  I was told that I could try using some socks...  It sounds like it could work..  The intake needs some type of restriction to run properly from what I understand.  Could the air/fuel ratio be changed to allow a less restrictive airflow? 

Lastly, would I be better off running the exhaust pipes into one muffler (like the stock GS), or run dual pipes?