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Post by captain chaos on Nov 4, 2014 12:10:45 GMT
Hi,
rewiring an 1100 ESD, and trying to remove all the shit that is not needed for making the engine run/lights work.
The speedo will be aftermarket anyway so I want to remove the control unit. I assume it's not as easy as unplugging and discarding it, I remember from the old site that some connections have to be modified or bridged.
Who can help me out?
Or maybe it's easier to make a new loom from scratch (without all the crap Suzuki put in it originally)?
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Post by arnout on Nov 4, 2014 17:59:22 GMT
If the ESD control unit is the same box ("monitor unit") that Suzuki fitted to EFE's then I think I can help with this.. As the monitor unit on my EFE was already on it's way out (several warning lights flashing at random moments) when I bought the bike years ago I soon started looking at how to get rid of this box.. Removing the unit would also create some more space under the tank for accessing the carbs and other wiring which is nice.. Right.. I too remember the topic on the old forum about it and me responding to it.. Had a quick look in my notes and even found what looks like the old response (or an edited version I emailed to Danish some years ago).. But first a quick answer perhaps: No, you cannot simply unplug the box.. You need to create a bypass for some of the wires that connect to the monitor unit.. Here's the copy-paste (don't remember any specifics about it anymore, so cannot verify atm if it is indeed fully correct..  ) : Oh.. I think I may have a sketch of the connectors and extra wires somewhere.. Can't find it right now, but will look some more or make a new one if needed.. |
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Post by captain chaos on Nov 4, 2014 19:35:11 GMT
Thank you very much Arnout.
By the way how was the beer I brought you?
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Post by arnout on Nov 4, 2014 23:06:53 GMT
By the way how was the beer I brought you? Surprisingly good!  Very smooth taste.. Would've enjoyed the other bottle too..  Btw.. Found the sketch of how to run the bypass wires on the connectors after removing the unit, but it's very sketchy/scratchy and might cause more confusion than it's worth so I'd probably better not scan and post it.. Scanned it anyway.. A picture of the actual wires on the bike would be clearer but I think I taped up the whole thing.. Well, it shouldn't be to difficult, just keep the block connectors on the loom intact and make some extra bypass wires with crimp-on spade connectors so they can be pushed into the "open" block connectors.. Oh.. Found a slight difference between my sketch and my description.. Oops!  It has the 2 brown wires on the 9-pin connector hooked up together instead of one of them connected to the main lighting wire (Y/W).. Well, it probably works either way but running the bypass wire between the brown spade connectors is the easiest to do.. |
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Post by captain chaos on Nov 5, 2014 10:12:24 GMT
Thanks, I'll have a look at it.
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Post by captain chaos on Nov 5, 2014 13:00:10 GMT
just had a quick look.
On the ESD, the 8-pin plug has only 7 wires in it on the loom side, 8 wires on the control unit side. That's the only difference I can find so far.
Although when I add up all the wires in your description, I count 16 wires and not 17.
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Post by strangewayz on Nov 5, 2014 17:39:04 GMT
On my 711 ET I used an EFE wiring loom (& EFE engine) & completely de wired the monitor box.
I can understand electrics if I look at a manual, not my specialist subject but it was easy to do.
If the instructions already posted don't nail if for you what I did was to look at a typical Suzuki wiring loom without monitor box for say the main headlamp beam circuit & then compared that to the EFE wiring diagram.
That told me what extra wiring the monitor box needed for that circuit & also how the circuit could be wired to bypass it.
I did the same for each circuit that went into it.
Of course you loose the function of the idiot lights that the monitor box controlled but everything else on the EFE clocks that I am using & with the loom itself works fine.
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Post by arnout on Nov 5, 2014 17:43:14 GMT
On the ESD, the 8-pin plug has only 7 wires in it on the loom side, 8 wires on the control unit side. Hmm.. That doesn't seem right.. Just checked on ESD and EZ wiring diagrams (UK and US models) and the unit is hooked up exactly like the later EFE/1150 bikes.. Maybe the missing wire was accidentally ripped out (and cut off) on your bike? What wire is missing according to the diagram? That's the only difference I can find so far. Although when I add up all the wires in your description, I count 16 wires and not 17. Huh..? Ah right, I forgot to include the G/W (side stand warning light)..  Oh well, important bit is just fitting the bypass wires and leaving the rest disconnected.. The drawing on my sketch is pretty self-explanatory in this regard, I think.. But is always better to double check the colours yourself of course..  But to simplify my earlier cut'n pasted story: |
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Post by captain chaos on Nov 5, 2014 18:20:46 GMT
Ok, I'll have a good look at the wiring diagrams. And probably end up making a new loom from scratch.
The bike is pretty minimalist, no sidestand switch, no useless crap like number plate light and fuel level, oil temp and gear position indicator, just a small electronic speedo/tacho unit, and some lights. Also I want to remove the one phase of the generator going through the headlight.
Considering the condition the loom is at the moment I guess it's easiest to make a new one.
Oh and I will post some pics of the bike when I won't forget to bring my camera to work.
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Post by arnout on Nov 6, 2014 17:25:02 GMT
Well, if the loom is indeed in a poor state overall (burnt wires, cut up sections, frequent shorts) then you might be better off swapping it for another one.. [rambling mode] Making a new loom yourself is a nice project to some (or "hell" to others  ) but don't mistake it for an easy job.. If the ESD were a customer bike you're working on you'd never get the hours back you'll need to invest making a loom from scratch.. Also the 3rd phase mod is a very simple one on a stock loom.. The nice thing about making your own loom though is that you can choose what parts to copy from the stock loom and what parts to leave out.. Leaving out wiring for the fuel level gauge, oil temp gauge, the gear position sensor, and the license plate light -like you suggest- wouldn't be my choice as I think these are all very useful things to have (if not legally required in case of the license plate light).. The loom I made for my Kat was going to be minimalist too, but in the way that it is a lot less bulky (hardly any block connectors and thin wire).. I still kept all gauges and light intact and even added a diy gear pos. indicator.. Scrapped the ign. switch for a relais under the seat eliminating the main power wires running to the steering head and back..) Using proper thin wall tracer colour wire sticking close to the Suzuki colour-scheme makes life a lot easier not just for making the loom but mostly when it comes to doing repairs/mods after some time.. Last tip (I promise ) use non-sticky pvc-tape to cover the loom.. Easy to use and doesn't make a sticky mess.. [/rambling mode] |
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Post by captain chaos on Nov 6, 2014 19:42:47 GMT
Had a good look today.
I ripped out all the stuff that's not needed: control unit + all its wiring, oil temp and sidestand and fuel level circuits, and some more small stuff (license plate light will be integrated in the rear light). And I simplified what's left of the loom. Now it looks a lot cleaner.
Might not be needed to make a new one, it is not completely FUBAR.
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Post by captain chaos on Nov 6, 2014 19:49:12 GMT
If the ESD were a customer bike you're working on you'd never get the hours back you'll need to invest making a loom from scratch.. and not only the loom.... if the owner was to pay me normally for every hour I put in the bike, I would be nigga rich now. No, I'm mostly doing this because I enjoy doing it. Of course I will get paid but not the usual amount. Here's some pics by the way:    |
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Post by captain chaos on Nov 7, 2014 16:59:06 GMT
well.... after removing all this shit from the loom  and reconnecting lights and speedo and stuff  it works!  Now cutting everything to the correct length, making new plugs, and taping it all up. Thanks Arnout and Alan for the advice. |
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Post by bigkenx on Nov 7, 2014 17:26:34 GMT
Far to tidy in that workshop captain , and your tiles look like a wiring diagram drawing
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Post by arnout on Nov 7, 2014 21:14:03 GMT
Good job on getting most of the wiring done so quickly..! (I'm sure not starting from scratch helped a lot here..  )The ESD build looks very nice and tidy so far (fresh paint?).. Not keen on the headlight though (but I've been criticized for that myself..  ) The stock swingarm is a looker but perhaps not on par with the upgrades on the frontend? Looking at the shock extenders a new set of adjustable shocks wouldn't go amiss either (if the budget allows).. Meanwhile maybe start a project topic on this bike now? Oh btw.. You might want to consider repositioning the coils higher up inside and between the frame rails.. This would make taking off the valve cover much easier.. This also hides them from view.. |
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Very smooth taste.. Would've enjoyed the other bottle too.. 
It has the 2 brown wires on the 9-pin connector hooked up together instead of one of them connected to the main lighting wire (Y/W).. Well, it probably works either way but running the bypass wire between the brown spade connectors is the easiest to do.. 
Oh well, important bit is just fitting the bypass wires and leaving the rest disconnected.. 
) but don't mistake it for an easy job.. If the ESD were a customer bike you're working on you'd never get the hours back you'll need to invest making a loom from scratch.. Also the 3rd phase mod is a very simple one on a stock loom..
)