GS 450 LD (GL51D)... wiring diagram?

[ST1100Y]

Yeah... got an assignment... lucky me...



probably an '85, but data on Suzuki's is pretty sketchy...
"customer complaint": fuel gauge not working (almost failed MOT for that...)

Long story short: someone tinkered with the fuel gauge, allegedly installed a new pointer...
I found that its now dropping instead raising when you flick the key to ON...
I'd like to avoid burning up the instrument coils, hence in search of a proper wiring diagram or even a photo of the backside, showing the wires...

The completely stuck/seized fuel petcock is another issue to attack...
I'd rather have a new one + gasket around before even touching it...

TIA...

 

[bdalameda]

Yeah... got an assignment... lucky me...



probably an '85, but data on Suzuki's is pretty sketchy...
"customer complaint": fuel gauge not working (almost failed MOT for that...)

Long story short: someone tinkered with the fuel gauge, allegedly installed a new pointer...
I found that its now dropping instead raising when you flick the key to ON...
I'd like to avoid burning up the instrument coils, hence in search of a proper wiring diagram or even a photo of the backside, showing the wires...

The completely stuck/seized fuel petcock is another issue to attack...
I'd rather have a new one + gasket around before even touching it...

TIA...

If it has a fuel gauge inside the tachometer it is a 1985 or later as earlier models had no fuel gauge. In the US there are quite a few instrument clusters available on Ebay.

 

[ST1100Y]

If it has a fuel gauge inside the tachometer it is a 1985 or later as earlier models had no fuel gauge.

Yep, figured that out already (after at first chasing that [GL 51 D] model code on the headstock nameplate... Suzies are weird... )

In the US there are quite a few instrument clusters available on Ebay.

Monitoring some, but by the sod state of that rig, is she (the owner) not really keen on throwing money at it...

 

[ST1100Y]

Alright had another session on that old Suzie cruiser...

first replacing that manual fuel petcock...
of course did that lady not run the tank empty
so a bit of splish-splash as the old valve one wouldn't turn off...
Carefully cleaned the tank's bottom surface with my Bosch tool and a (brass) wire wheel
(the old valve had already been glued on by someone in the past...)
New one fitted without a fuss... a slight smear of silicone grease on the O-ring, Loctite on the bolt threads...

Having the tank off also provided access to check on the fuel sending unit, which proofed OK...

Had another look at the fuel gauge...
The criminalistics POV "... what have they done to it?..." paid off...
Someone installed a new pointer... was the instrument's rotor "zeroed in" during this?
Carefully pried the (new) pointer off the tiny axle, attached the instrument to the bike and flicked the ignition on... ah-ja...
Having an empty tank was ideal, a few actions with a wire hook to move the sinker arm between E and F helped
to "re-calibrate" the fuel gauge... its alive!
After pouring the previously drained 5ltrs back in, it settled a bit below half... nice...

However is now an other issue raising its head: riding around the city with the headlight on drains the battery...

@ 5000 rpm barely 12.4~12.7VDC at the battery terminals...
stator winding reads 1.8 to 1.9 Ohm at all legs... quite low...
@ 5000 rpm stator output reads 14.2~14.8VAC... way too low...
(IIRC the 26A ST 3-phase genny winding delivers ~60VAC, the old 450cc Suzi manual even states 75VAC...)

So another appointment next week...

 

[bdalameda]

There should be three yellow wires coming from the stator - between any two yellow wires you should have 65-75VAC. You might have one bad winding out of the three.

 

[ST1100Y]

You might have one bad winding out of the three.

As written show all three windings only 1.8 to 1.9 Ohm, and deliver only between 14.2 to 14.8 VAC... so that thing is cooked...

 

[ST1100Y]

Alright, installed a new stator into that "duck hunter"...

Of course is the thing oil-cooled, so put a pan underneath when attempting to remove the cover...

New coils, new paper gasket, new crimp connectors and two hours later:
idle with low beam on: 12,8~13,2VDC, @ 5000rpm: 14,4VDC... TADAHHH, I fixed something...

That thing even features a "machine telegraph" (illuminated gear indicator)... impressive for an '85...

 

[ChucksKLRST]

Alright, installed a new stator into that "duck hunter"...

Of course is the thing oil-cooled, so put a pan underneath when attempting to remove the cover...

New coils, new paper gasket, new crimp connectors and two hours later:
idle with low beam on: 12,8~13,2VDC, @ 5000rpm: 14,4VDC... TADAHHH, I fixed something...

That thing even features a "machine telegraph" (illuminated gear indicator)... impressive for an '85...

It did not happen until you post some pictures of your success.

 

[ST1100Y]

It did not happen until you post some pictures of your success.

LOL!
a) was kinda busy... (the lassie is also on unemployment, so I rushed to keep the hourly charges at bay...)
b) didn't care to fumble my brand new phone with oil soaked paws...