Hayabusa wiring loom.

[ottocycle1-21]

Hello everyone,

I am trying to tidy up a Hayabusa loom as much as I can. I have the wiring diagram but am not able to read it properly. I have a few questions and would appreciate the feedback.

Instead of jumping wires on connectors like the clutch, side stand and engine stop and still retaining the relay, beside the fuse box, I want to remove the relay completely. It ties into a number of fail safe systems.

ENGINE STOP: Orange/Black wire goes from connector block to relay, but I do not know where it goes from there. The Orange/White feeds the starter button and then the coils. If I bypass the relay what do I do with these wires. I do not know how to read the relay diagram.

STARTER BUTTON: Yellow/Green goes into ECU and starter relay. What is on the other side of this---a ground wire?

CLUTCH LEVER: Black/Yellow-jump to ground, Black/White? (Is the Black/White wire standard ground for Suzuki?

What does the gray from the ignition to instrument panel do? It seems to me that it iluminates the gauges. Is this right?

How do I bypass the timing retard system?

I do not want to apply a voltage "willy nilly" to the loom in hope of figuring it out.

I found an explanation of what Westfield do to their looms but they tend to keep more of the original Suzuki than I would like. Maybe this should tell me something.... :) :):)

Has anyone found a link explaining the trimming of the Hayabusa loom?

Is there a better way of binding the loom other than electrical tape?

Thanks,

Ottocycle.

[Bob Mortimer]

On Thursday 29 Oct 2009 01:03:44 ottocycle1 wrote:

> Instead of jumping wires on connectors like the clutch, side stand and
> engine stop and still retaining the relay, beside the fuse box, I want to
> remove the relay completely. It ties into a number of fail safe systems.

You don't need to retain any of the relays or the fuse box.

> ENGINE STOP: Orange/Black wire goes from connector block to relay, but I do
> not know where it goes from there. The Orange/White feeds the starter
> button and then the coils. If I bypass the relay what do I do with these
> wires. I do not know how to read the relay diagram.

Orange/White is the main ECU supply, connect this to your ignition switched
12v. I haven't specifically documented the Orange/Black from stop switch to
relay but am pretty sure it went in the bin.

> STARTER BUTTON: Yellow/Green goes into ECU and starter relay. What is on
> the other side of this---a ground wire?

When you apply 12v to the Yellow/Green it energises the starter relay, so
generally you'd give it a 12v supply via your starter button.

> CLUTCH LEVER: Black/Yellow-jump to ground, Black/White? (Is the Black/White
> wire standard ground for Suzuki?

Yes, just connect the Black/Yellow to earth, and yes, the big Black/White wire
is the bike loom earth.

> What does the gray from the ignition to instrument panel do? It seems to me
> that it iluminates the gauges. Is this right?

The wiring diagram differs from one model year to another but unless you're
using any of the bike loom lighting wiring or using the bike clocks you don't
need to worry about it.

Apart from the wires mentioned above, the wiring for the various sensors
(atmospheric air pressure, engine coolant temp, intake air temp, intake air
pressure) and the fuel pump relay you can strip everything else out. I
stripped out the wiring for the horn, fan motor and its switch, fan relay,
vacuum control solenoid valve etc.

You also need:
 * to bypass the tip-over switch - my notes say 62k ohm resistor  
 * Orange/Yellow from ECU to ignition switch needs 100 ohm resistor between it
and earth

> How do I bypass the timing retard system?

Buy a TRE, I got one of these:
http://cgi.ebay.co.uk/ws/eBayISAPI.dll?ViewItem&item=300351315364
Although an old message I have from someone on here says 6k ohm resistor wired
in with gear position switch.

> Is there a better way of binding the loom other than electrical tape?

Proper (non-adhesive) loom tape is preferable. I think it's flame resistant and
it's easier to remove when you want to modify your loom again later.

B