1979 TS 125 - electric issue.

mqqn · Posted: Sat Mar 06, 2010 12:28 pm Post subject: 1979 TS 125 - electric issue.

Hi Folks -

I have been working on a TS 125 - had to take it apart and clean everything. It is a bike that was purchased new, ridden very little and then was left sitting for 15 years or more.

I have it all back together and looking great, running perfectly.

One problem I have is that the kill switch does not stop the bike.

I am not very experienced with troubleshooting electrics, so I would appreciate any suggestions on a plan of attack.

I am going out right now to fix the front tube and apply the Suzuki graphics to the tank.

I'll check back in later this evening - I will be working on the bike tomorrow too - I would like to get this bike out of my garage so I can have the room back.

Thanks and best regards

mqqn

tcanough · Posted: Sat Mar 06, 2010 5:08 pm Post subject: Hello mqqn

I'm no genius when it comes to electrical , but the kill switch is an easy affair . You may be wired incorrectly , you may have a bad switch or you may have an open . Assuming the switch is in good working order that should leave two wires [usually a black and a green ] . The black should go to the coil and the green should go to ground . When you hit the kill switch it grounds out the coil . Usually all of the green wires by the headlight cluster are grounds and you should have a split off of the coil that goes directly up to the black wire . Hope this will help you . I know the schematic can be a nightmare until you get acclimated with it . Good luck !!!

dorT500 · Posted: Sat Mar 06, 2010 5:13 pm Post subject:

spider web in the contacts/switch housing..............this is my stock answer. Embarassed

Gotta be right one of these days. Wink

dorT500 · Posted: Sat Mar 06, 2010 5:18 pm Post subject:

> TS125C wiring- colored diagram from an individual on another site. Click on to enlarge (kinda)

pd · Posted: Sat Mar 06, 2010 6:31 pm Post subject:

I don't see a 'Kill' switch in that schematic . Just the ignition switch.

dorT500 · Posted: Sat Mar 06, 2010 7:21 pm Post subject:

I did not either.

bobbyjim · Posted: Mon Mar 08, 2010 7:53 am Post subject:

[b][i]I have the factory original service manuals for the '78-'80 TS125 models. The '79 is a TS125N and I have the service manual and wiring diagram with the switch in it. If you need any help just PM or email me.

mqqn · Posted: Tue Mar 09, 2010 5:04 pm Post subject:

Hi folks -

Thank you for the diagram -

I should mention that the ingition switch will not kill it either -

I had the headlight bucket off of the machine to hammer the headlight bracket into shape (bent from a small crash sometime in the past...)

I also had the luggage rack and rear taillights off of the bike to again straighten things out.

I must have screwed up a ground or something -

I'll be spending some quality time with it over the next couple of days. I really want to get this back to the owner and out of my way.

Thank you all for your help - and I may have to als bobbyjim for help if I cannot trace it down the old fashioned way.

You guys are the best -

best regards -

mqqn

dorT500 · Posted: Wed Mar 10, 2010 2:26 am Post subject:

mqqn · Posted: Sat Mar 13, 2010 10:48 pm Post subject:

Hi dorT500 -

I took the bucket back off and double checked for those grounds - this bike has the same exact mounts and internal reinforcing nuts, but no grounds there.

The turn signals are grounded to a common ground - all of that looks great.

The schematic above is invaluable.

Tomorrow I'll check out the rear wiring - I am thinking that I may have not gotten one of the grounds correct on the rear fender mount - I'll report back here when I get it all figured out.

If I can just get this problem fixed it can go back to its owner and I can get my Connie ready for spring.

Thanks again for all of your help - I appreciated it greatly .

best regards -

mqqn

mqqn · Posted: Sun Mar 14, 2010 2:10 pm Post subject:

Hi folks -

I checked out the wiring in the headlight and the front turn signals - it all seems fine and per the schematic posted above.

I also took apart the kill switch and cleaned it all up - all looks great in there.

So, the one place I have a concern about is the little jumper ground wires on the rear turn signals -

Here are a couple of (very large high resolution) pictures of the wires I am talking about - Maybe I have them on the wrong side of the rubber washers?

http://www.iammoon.com/images/bikes/1979%20Suzuki%20TS125/DSC_9689.JPG

http://www.iammoon.com/images/bikes/1979%20Suzuki%20TS125/DSC_9690.JPG

The neutral light and headlight etc all work, but the run/stop switch does not stop the running engine, nor does turning off the ignition switch (key).

Any ideas on where or what to be looking for?

Best regards -

mqqn

dorT500 · Posted: Sun Mar 14, 2010 7:19 pm Post subject:

I was going to ask you if there was a luggage rack involved here. I went ahead an read an earlier post by you and sure enough there is/was a luggage rack. Normally, At least on some bikes, the turn signals would be screwed into some tube brackets that then screw into the frame, but if a luggage rack was added by a dealer or individual the original tubular turn signal mounting brackets would be removed and the turn signals bolted directly to the luggage rack. If the luggage rack was adjustable type, then the luggage rack would need to be grounded. The adjustable type would have plastic sleeves on the two separate rack pieces that slide back an forth to accomadate a few different bikes. So the luggage rack would not be grounded on the front mounts of the rack to the frame.The point at which the rack would mount at the back(where rear fender mounts)has rubber grommets and cannot ground there. Thus the short jumper ground wire. It would be bolted to the back area of the rack(with the turn signal shaft) and then bolted to where one of the original turn signals/brackets were originally. All this would only apply if the luggage rack you have is a three peice adjustable. Stand by...I think I have a couple of pics that will show what I am talking about.

Edit: Please note this text change...Thus the short jumper ground wire. It would be bolted to the back area of the rack(with the turn signal shaft) and then bolted to where one of the original turn signals/brackets were originally.

dorT500 · Posted: Sun Mar 14, 2010 7:43 pm Post subject:

Well...this is probably the best I can do. May not even be the type you have on the bike. So in a few words.....if the luggage rack is not going back on ,then you don't need that short jumper wire. The turn signals wil be grounded when you screw them into the frame or original tubular 90 degree brackets. This is the luggage rack I use on the T500 and hope to have showchromed sooner or later. Could cost $300.00, maybe a little more, to do it though. Sad

The plastic black sleeves that go around the two individual pcs. that mount the front of the rack to the frame are not in the picture.

mqqn · Posted: Tue Mar 23, 2010 3:34 pm Post subject:

Hi folks -

I wanted to post an update -

I found the issue with the electrics on this bike -

The main wiring harness has two white plastic multi-connectors up under the gas tank, and one of those was not clipped in securely -

I noticed that when I turned the bars to the left fully, everything would start working as normal, then would stop working when the bars were straightened.

A little messing around with the wires while she was running and I quickly identified the wire, then traced it back to the connector.

She's running like a top now - and the owner will come pick it up this Friday.

Thanks for the help in this thread - I REALLY appreciate it.

Very Best Regards -

mqqn