Suzuki 2 Strokes

I just got my 76 GT750 on Saturday and did some tinkering. I got a new battery and contected it. turned the key and the voltage regulator fried. I noticed an orange wire that had 4 other orange wires soldered to it. not sure of it. So to make things more simple, I am in the market now for a set of harnesses. I will post up some piocs here shortly.

here are some pics of what i got done so far. I basically striped down alot of things to clean and check for other issues.

here is a pic of the harness where it has been soldered. Can anyone tell me if it is supposed to be that way ? My book doesnt show me.

Yes, that's normal. Orange has to go to all the circuits including all 3 coils, so it splits and the way they do it is to just crimp or solder the connections.

A bigger question is where is teh dead short to ground? Probably the field coil in the alternator.

not too much of an electrician. not sure if there is a short or a couple of wires touching each other that caused it. when i turned the key on, the neutral light came on then the i tried a few functions. Lights, horn, starter, etc.... nothing happened. turned the key off and then checked a few donnections then turned the key back on. neutral light didnt come back on and then the voltage regulator send a cloud of smoke out through the garage. I took it off and the wires were fried but the regulator looked fine on the inside. Instead of jacking with tracing wires, I decided to get new harnesses instead. I even played hooky from work today to tinker with it. Too much fun........Cant wait till its running.

I hate to say it but Paul Miller is the only source I know of for the needed harnesses. Expect to pay about $150 for the pair.

I think $150 for the pair is better than a mess of fried parts from trying to figure out where the problem lies. How do I get in contact with this Paul person ?

He has the GT750 wiring harness set listed on eBay.
http://cgi.ebay.com/ebaymotors/Suzuki-g ... 500wt_1182

Prices for NOS parts have been gradually climbing. His current price for the wiring harness set is $189

Thank you. I will check it out tonight.

Would be a good idea to fit a modern solid state regulator/rectifier from Electrexworld in the UK or Anthony at Oregon Motorcycle electrical. And check the alternator field coils and charge coils before you connect anything.

You may also want to think about adding some fuses and relays to protect things.

here ya go
unfortunately no lighting
http://www.electrexworld.co.uk/stk-235- ... 390-0.html" onclick="window.open(this.href);return false;" onclick="window.open(this.href);return false;

http://www.electrexworld.co.uk/rr77-reg ... 863-0.html" onclick="window.open(this.href);return false;

Looks like you'll have a nice bike when you're done.

For info about the GT750 alternator, see page 15 in:
http://www.ozebook.com/compendium/suzi/suzidata1.htm

Rotor field coil resistance should be around 10 to 20 ohms.
Stator field coil resistance should very low.
Both coils are insulated from their metal housing. Resistance between coil & metal housing should be infinite.
Plenty of replacements are available on eBay if they are bad.

Oregon Motorcycle Parts has a rectifier & regulator that are direct replacements for the GT750 parts. Cost is about $100 for both.
http://www.oregonmotorcycleparts.com/

I've had 2 bad rectifiers. Seems to be a good idea to replace it now to avoid future problems.

Coyote wrote:I hate to say it but Paul Miller is the only source I know of for the needed harnesses. Expect to pay about $150 for the pair.

These harnesses (#1 and #2) are still available from Suzuki in the UK (£162 ) and Germany (€130) - probably other countries also. Prices obviously vary due to exchange rates, but it does pay to check other countries.

Thank you for all the help, guidance and comments. This helps me press on with this project. All of you are going to make this project really easy for me.

I have already considered the regulator and rectifier from Oregon Motorcycle as one of my next purchases. The harnesses, well, I am really wanting to go new with them anyways since they are kinda stiff and that bothers me. The other thing I ran into is the boots that connect the airbox to the carbs are so stiff and they have shrunk some. I had all kinds of heck trying to get them fitted back on. I gave up and decided to try to get new ones if they are still available from Suzuki. I took a few pics today with it in the driveway I wil share for your viewing pleasures and comments.

That did clean up nicely eh ? I may ask you to let me use a couple of photos in the Field Guide as it looks to be a fairly unmolested example ! I see you've left the fuel petcock in the 'Prime' position - was there a reason this this as it can cause flooding. You know there is no 'off' position with these as they are vacuum operated ?