Hey all,

Been thinking of this for my swap and I needed some info.  I mentioned it to Psyber and he was thinking of upgrading as well.  But I still need to know a couple of things.

I have a '92 with weathered and sticky controls/tubes.  When I put my k9 FE on I wanted to upgrade the controls, ie kill switch, lights controls, and throttle tubes.  I did some small research and it would seem that I cannot add 2003-ish throttle controls as they have a sending and return linkage for the throttle.

Mainly I am thinking I can't do any years that have a three part jet system in the carbs or am I wrong?

What is the latest year control package I could add to modernize my controls that will use a single throttle cable and also mate right up to the exisitng setup of a '92?

Thanks all.
Jon

I haven't tried but couldn't you just use the newer throttle with only 1 line attached like the old ones??

-Jessie

maybe the old throttle tube will fit the new control, then you'll just have an extra hole on the bottom of the control but you will still retain your single cable/throttle setup.

I actually have a buddies 2 GS's. 1990 and 2001, both are in rough order and we are transplanting the heart of the 01 into the 90. I will take a look at the controls and talk to him to photodocument a possible swap. I'll let you know O.C.D, as it would allow for definitive answers without a loss in buying the parts and not having them work. May have to do this on tuesday though....

baltimore beat me to it.

the throttle tubes will fit, you will have an extra hole on the bottom for the newer control.

The catch, both plugs are different on right and left controls. They will work, just have to merge harnesses with the old plugs. It's real easy, but theres no avoiding it. Just as if you wanted to merge GSXR controls into the GS etc... you'd probably end up with a bunch of accessory looms of wire because who knows how things are routed.

Will post pics later.

New (left), Old (right). The hole in the upper right corner holds the throttle cable (single). The hole on the upper left of the new control (left) will be left open.


however,


New plug (left) is much different than old plug (right)....will require a small wiring modification to merge harness into the old one. There are some redundant loops in the new harness which won't really be of much use in the old harness.


choke and turn signals housings
new (right) and old left)


again, wiring is different, easy, and unavoidable

I have thought about this too. Thanks for posting it up. Will you just be able to push out pins or will the actually need to be spliced?  Are the wire colors similiar or totally different?

plugs are 100% different. you can push the pins out but it would be moot. The old plugs are both female, the new plugs are male...

colors looked similar, but you'd have to cross reference the wiring diagrams to be sure.

Thanks for all the pics Psyber!!!  I haven't been on all day and this was great to see.

So, it looks like you just use one less cable hole and then yank out the soldering iron and chop away.

You going to cut it up and try or leave it alone?  I will probably cut it up and try.

Thank you soooo much for those pics and thank your buddy as well.

Jon

yea just whip out a wiring diagram and have at it. Shouldnt be hard. These controls belong to a buddy, we are going to swap the entire harness and motor over from the 01 to the 90, so it would be plug and play for him.

lmk how it turns out. I wouldnt mind updating my controls some day, but new pistons are on top of my list now

Bringing up that dead here but,...........

Last night I started the swap in the wiring for the new controls.  In the Haynes manual there are many different years (obviously) of wiring diagrams.  SO far I am literally daunted by this.  I hate wiring though.  Has anyone done this yet and can lend info to my issue? 

I have a '92 wiring harness and '06ish newer controls.

The newer controls have many more wires as opposed to the older ones?!

I feel stupid as I am not, but I am just not confident in wiring. 

This is completly possible.  I have swapped hand controls from the F model onto my 1990 model bike.  Unfortunately I did this over a year ago and I don't remember all the wiring that was switched.  I'll search back through some of my old posts to see if there was something detailing it.  You would think I would have been smart enough to post it.

Thanks,

Nick

Lol, we all wonder what our brains think at times.

If you do find anything please let me know.  I would really appreciate it. 

Well I have the pics to prove it but I couldn't upload them before work.  BUt, I got it done last night!!!!

What a pain in the *&&&%#$$$##$****@*#**$^!

The '06 controls have more of the wiring in them then the '92 ones.  What I mean is there are not as many exterior wires in the actuial controls.  God bless the volt meter is all I can say.

I did learn a couple things I never knew.  Like, the newer models have passing circuits?  How/what does that do.  I removed it but I am curious to know now.

"Passing circuits" sometimes called "flash to pass" are common on european bikes, where the custom is to flash high beams before passing another vehicle.  If all the components were there, you would see a trigger-like switch for the left index finger. 

I'd like to get my hands on a European model switchbox myself.

Understood.  The wires for the passing switch were integrated into the starter switch which I thought was really odd?!?!  I would think using that same switch would fire the starter while driving.  Or it could disable the starter and enable the passing mode?

Did I buy a UK model control?  I wouldn't think so.  Do US versions have this circuit as well?

I think gunslinger had some confusion with his, which made me think the newer US models also have the wire, but no switch.   

According to the wiring diagram in the wiki: http://img102.imageshack.us/img102/9910/ukekpu8.jpg
it's not integrated in the start circuit.

Even the US models are wired that way, it makes it so Suzuki doesn't have multiple wiring harness to make.  They used one across the board.

Unfortunately I couldn't find anything that I wrote up for this switchover, but I do remember there were wires from the F model that were not needed/reused for the E model.

On a side note, the starter button won't engage the starter unless the clutch lever is pulled in.