wiring for suzuki t500

zrs1919 · Post by **zrs1919** » Sat May 30, 2009 4:18 pm

hey guys everything is coming along for the build...but I really want to eliminate as many wires as possible...I took the headlight off and realized it was a junction. Do any of these wires have anything to do with the ignition/coils? I really want to get rid of pretty much everything and have some toggles...

any ideas or help?

thanks
zac

zrs1919 · Post by **zrs1919** » Mon Jun 01, 2009 8:11 am

can nobody help me with this?

Suzukidave · Post by **Suzukidave** » Mon Jun 01, 2009 8:48 am

Zac , check out this site ... here there are loads of 500 info http://www.ozebook.com/compendium/t500index.htm

zrs1919 · Post by **zrs1919** » Tue Jun 02, 2009 7:15 am

I really couldnt find the answer to my question there....although it was very informative on other subjects...
Im just worried that if I get rid of the headlight nothing on my bike will work.....
thanks

elbert · Post by **elbert** » Tue Jun 02, 2009 11:08 am

I'm not 100% sure, but I think you will still have ignition and tail light if you disconnect everything in the headlight. But if you wan't to remove most of the electrics on the bike I think it would be better to build a simple harnes from scratch.

zrs1919 · Post by **zrs1919** » Tue Jun 02, 2009 12:59 pm

couldnt I just have a toggle switch setup, running from the battery, to the toggle, from the toggle, to the ignition, and also the stator? and then from the stator to the rectifier, and then back to the battery?

diamondj · Post by **diamondj** » Tue Jun 02, 2009 1:57 pm

Hey zr,

I'll admit my confusion now - what are you trying to do by eliminating part or all of the wiring harness? Are you setting up the bike for racing? Or just looking to clean things up? Here's a link to a color wiring diagram:

http://home1.stofanet.dk/optik/suzuki/t500eldiagb.htm

I guess you'll need to figure out what you need and what you don't need and go from there?

Jim

zrs1919 · Post by **zrs1919** » Tue Jun 02, 2009 2:04 pm

I want to eliminate all the wiring and start fresh as it will be a complete race bike

zrs1919 · Post by **zrs1919** » Tue Jun 02, 2009 2:06 pm

that shows the coils running into the turn signals as well....

I dont get it

tz375 · Post by **tz375** » Tue Jun 02, 2009 2:55 pm

In which case, step away from the motorcycle and no one will get hurt.

You cannot wire it the way you suggested. Start from scratch and wire it with a kill switch as required by all race organization rules. Get a set of rules and then follow the wiring diagram carefully and compare it to your bike (for the ignition circuits).

Try to draw out the part of it that you need, or start with a clean sheet of paper and just draw what you think you need.

Is it a T with points or a GT with magneto and CDI box?

This stuff is not rocket science and is far simpler and working on a modern bike. No pressure or temperature sensors, no tps, etc etc. It's really basic stuff.

Do you have a handbook or access to one online? if so check out the part on Ignition.

zrs1919 · Post by **zrs1919** » Wed Jun 03, 2009 8:49 am

its a T500...

diamondj · Post by **diamondj** » Wed Jun 03, 2009 9:50 am

Hey Zac,

As TZ said, you'll need to decide what ignition you want to run to better determine what wiring you'll need. I know Muzza has a section on race prep on his website but I don't recall if he covers wiring or not:

http://www.ozebook.com/compendium/t500index.htm

My race bike is based on a GT500 and it uses the PEI ignition system that Suzuki added to the GT500 in 1976. Since the PEI is pretty much a separate circuit, it's easy to remove all the street related stuff you don't need.

For a T500 based racer, a self-generating magneto type system would be better as you can pull the whole harness and run without a battery. Trouble is, there not a lot of options for this type of system on the market currently. Rex Caunt offers a complete system for the T500:

http://www.rexcauntracing.com/pages/pro ... icing.html

but it's a but pricey at £484.83 ($793.34 US currently).

There's these guys in the UK as well but they don't list any prices:

http://www.roadandraceignitions.co.uk/14.html

And then there's these guys selling a racing system for just under $400:

http://www.powerdynamo.biz/eng/systems/ ... 85main.htm

I have heard of people adapting PVL systems to the T500. The Yamaha Banshee 350 would work although you'd have to figure out how to adapt the rotor to the T500 crank and figure the correct timing. I've seen complete PVLs for the Banshee sell as low as $99 on Ebay... These guys offer a PVL for the T20 that could be adapted:

http://www.pentonracingproducts.com/application.htm

Otherwise if you're going to use the stock points, coils, etc. you'll need to keep a battery in the set-up (although you could run with a small gel battery hidden under the racing seat) and you'll have to decide if you're going pull the rotor and gut the stator and run total loss or not.... Either way you would probably be better off building a new harness rather than trying to use parts of the exisiting harness.

Jim

tz375 · Post by **tz375** » Wed Jun 03, 2009 8:20 pm

Also check out

http://www.electrexworld.co.uk/stator-k ... 537-0.html

All those listed by Jim and the one above are self generating units which work for all intents and purposes like an old school magneto. That is teh best system to use IMHO.

Next alternative is to adapt an electronic trigger such as a DYNA system from say a Suzuki 1000 4 cylinder. It has two pickups and one or two magnets (I can't remember) which.

If it has two magnets 180 degrees apart, use one trigger/pickup and one double ended coil plus a small battery.

If it has ONE magnet use BOTH triggers and TWO coils.

Throw away 100% of the stock wiring and build a new loom using a new cut out. For drag racing you have to use a lanyard I believe, so get one from Pingel