04 gs500f missing parts/wiring mahem

[Ryanstalin]

I bought a gs500f for about $100, it wasnt complete. and im determine to make her road worthy again. so far I know she only had two owners. and one of the owners never even got it running again. plus the original owner had the bike stolen from him, this is when the wiring harness was hotwired. also the bike was wrecked. but not total, plus the title i have is good.
so the last owner said he bought it from the guy for his two boys to work on and fixed, he bought a few extra parts for the bike, and a hardcover haynes manual. also came was another wiring harness. but his boys never stayed on it for long. and their father just wanted to get rid of it. so far I believe my harness is an older model, and I tried to use the wiring diagram to make the 2002 and below harness to work. so far I still cant get anything to work, except for jumping the starter solenoid when you bypass it with a wrench.
+I have the ignition coils, and ignition control module hooked up
+I have the key ignition, battery, and both handle bars hooked up.
+I checked the clutch switch, and kickstand switch
+I have a good ground.
I have some other things hooked up, like the relays and such. the alternator/stator seems plugged in as well.
the wiring harness I semi-completed, has all good wires, and everything is traced. so where did it go wrong.

[Funderb]

have you tried the O.N.--O.F.F. switch?
but really! its easy to forget that one. Should have seen me one morning when it got bumped to the off position by a drunkard the night before... a child's ears would have melted. ( I meticulously put the button back to RUN every time i shut her down)


other than that, having a good battery is key, which you may have, seeing that the starter turns over.
What happens when you turn the key on? do the idiot lights come on?  is the ignition switch wired properly?

I find that putting the bike on the center stand in neutral makes all troubleshooting 10x easier. start there
go over your wiring set up over again.
1. check the fuse, there is really only one, and its covered up, as in, you have to remove a piece of rubber to see it.
2. check all connections involving everything. If there are two plugs plugged into one another that are different colors, they are probably incorrectly connected. There are... 10 plugs? including bullet connectors in the bike, and only 4 of them are wrong swappable, if I remember correctly.
3. Adidasguy loves electrical shaZam!, he'll be a big help too.
4. maybe replace the solenoid, but get the bike to turn on first.

[Ryanstalin]

no idiot lights. Im also missing the gauge cluster. the bike doesnt make any noise when turning the key to on. if the key was on. and I switch the killswitch off, and hold down the starter button, nothing happens. I dont even have my tail lights. and Most wires match up. atleast the colors of the wires. and its done by the wiring diagram of the book. my bike is up on the middle kickstand, with the other stand also down, because of the safety switch in the regular kickstand.

[Funderb]

the safety switch shuts the bike off when the side stand is down and the bike is in gear -  to clarify. you may know that already. I'm not sure if wiring in the inst. cluster affects the operation of the bike, it may, but i dont have the diagram in front of me. ehh. i vote -  assemble the bike completely, then you can work down from the top.

[Ryanstalin]

well I had the bike in neutral, so I dont think I would have that problem. My friends 250r ninja runs without the gauge cluster, I figure mine can to. I'll have to wait til the 19th to get the other parts. I was hoping I could figure out if the motor is any good before I buy the other parts.

[sledge]

and Most wires match up. atleast the colors of the wires.

Here is a tip.....they ALL need to match up!

What you need is the CORRECT harness for your bike and to ensure you are not missing any vital parts. Then someone with electrical know-how and experience needs to systematicaly check EVERY wire, connection, component and ground on your bike from front to back.

Sorry but I cant sugar coat it for you 

[Ryanstalin]

I understand. but If I have all the vital part connected and ran properly, I should atleast get a jump start. or a spark, I dont have spark. gauges and lights, turning signals are not required for most engine systems to run. I feel like Im forgetting something, If I dont solve it with the parts I'll buy. I will put it in a shop.

[adidasguy]

If you say GS500F that means 2004+.
Exactly what year? There is a slight difference in the harness between 2004-2005 and 2006+ (i.e. headlight cut off wired to the starter switch).

A new wiring harness is cheap for 2004+ models: often as low as $10+postage from pinwall cycles on ebay. if the wiring has been fuggled with, replace the wiring harness. Takes maybe an hour to do.

So first we need the correct year.

The side stand relay kills the bike.
If in gear, bike will not run if side stand down. Bike must be in neutral OR side stand up.

Bike will never start if clutch safety switch not closed and kill switch off (They are wired in series to the starter button). Clutch safety switch can be shorted. That switch will get destroyed if someone takes off the clutch lever without first taking off the clutch switch.

[Ryanstalin]

That last part makes sense because when I got the bike the clutch handle was in the box. My friend put it on. So of it was installed wrong the kill switch wouldn't work right? And I should be getting an 05 harness the 19th. But I can'twait to atleast see it fire once. Your reply was very informative btw.

[Ryanstalin]

I'm not sure of the placement of the battery, and starter solenoid. Does anyone have a picture so I can put it all back in the right spot. Everything else seems in the right spot

[adidasguy]

A service manual or Haynes manual is a necessity (I prefer Haynes over Clymer)
Wiring diagram is a must. The Haynes has them in color making it easy to follow. Get the book that covers through at least 2006.

The clutch switch wires can be shorted.

Can you get it to run when you short the starter solenoid?

order the book and pay for rush shipping or subscribe to Amazon Prime (30 day free trial) to get fast shipping for 99 cents

http://www.amazon.com/Suzuki-1989-2008-Haynes-Service-Repair/dp/1844258815/ref=sr_1_1?ie=UTF8&qid=1347225668&sr=8-1&keywords=gs500+haynes

[Ryanstalin]

I have a hardcover haynes manual. and the bike just rotates with the starter solenoid shorted.
I followed the important wires all to the right places. where is this clutch switch at, because I dont see it, is it in the sprocket case or on the handlebar? can I hotwire those wires to make it run?

[Funderb]

its a little on-off switch like on an old lazertag thing, should screw/bolt into the clutch lever assembly. two male blade connections stick out. in order to jump it, you have to connect the two wires that plug into it.

[Ryanstalin]

I'm going to try that tonight then. Yet I know the connectors your talking about I don't see anywhere on the clutch handle where they go. It's on the left side with the headlight stuff right?

[Funderb]

It looks like this:




Closer:




See those two wires coming into where the clutch lever is covered by that rubber thingy? they attach to a switchy thingy, held in by 2 #1 phillips head screws. smallish.  if that assembly is not there, you'll need to get one. not sure where to look. prolly easier to just strip and twist the two yellow wires together.

[Ryanstalin]

yeah I dont have that module thingy. I rather just tie the wires together, or jump them using another piece of wire. I have to try it tomorrow. I dont have any work or anything else to do.

[adidasguy]

Don't cut if there is a connector. Pull connector and stick in come wire.

[Ryanstalin]

i do Have to put out something
the two wires we've been talking about dont run the same way as you pictured. they run into the handlebar switch box

[Funderb]

meh, hook em together and see what happens.

[Ryanstalin]

thats what Im going to do. because I believe the wires going in there, but they come back out in that main harness part.