Gday fellas. My pickup wires on my 1982 S2 were joined via a connector, unfortunately when i pulled the connector apart, the plastic was so brittle that it fell to pieces. on one end of the plug the wires are labeled V and O, but not on the other end. The wires are 2 x plain white and 2 x black and white. How can I tell which way they connect?
I had a similar problem but even worse when I was restoring my Pantah 500SL which uses the same Bosch ignition as the SS, Darmah and S2 but as far as I can tell the wires were white, pale green, white/black and white black. This is picture of the connector to the pick ups. It was the state of the wires that led me to replace them but when I took it apart I was left with this : The insulation was so brittle it fell off as soon as the wires were moved all the way back to the pick ups. Below is a diagram showing the wiring of the connector that goes to the pick ups on the Pantah but since both your pick ups use white and white/black wires you're going to have to take the LH cover off to trace which is the vertical and which is horizontal.
Thanks Derek The pale green one you have looks like discolouration. I have taken the cover off, but the wires are shrouded all the way back to the pickups. I've tried checking with a multi meter but get no reading from the connectors to the pickup and I dont really want to take the whole thing off because it is set at the factory. Can the wires be removed from the pickup itself or are they moulded in?
It might have been discolouration but under the circumstances it didn't really matter. If you are getting no reading between the wires and the pickups you've got a problem. Do you get a reading across any of the wires? The resistance of the pickups should be 220Ω. The wires are moulded into the pickups. I managed to solder on new wires right at the back of the pickups. If you have to replace the wires you will have to take the pickup mounting plate off. There is no need to remove the pickups from it. Scribe a couple of lines against the motor that you can align to when re-fitting so that you don't loose the timing. When refitting the gap between the pickup and the raised bumps on the flywheels should be set to between 0.35mm and 0.40mm. This is what mine looked like after replacing the wires: I got replacement 4-way Molex connectors from Kojaycat.co.uk
Wow! Nice job. I did get a reading after all, they are within spec. I was just concerned that there might be an intermittent fault because I am getting misfire at around 3000 rpm and higher. Some of the other forum posts have suggested that they should be rewired, whether there are problems with them or not.
Same problem here - I did some research when checking the wiring and have put the attached note together - would appreciate any corrections please...
Just to add that you can get Kynar high-temp sleeving on eBay - take the old insulation off back to the sensor - cut the wires to around 10cm, and slide some Kynar 1.6mm sleeving over the wires. Then replace the main cable with high temp silicone 4-core, 7mm OD. I took the whole lot apart first to clean the sensors and wires properly. The assumption that the sensors are set at the factory then not touched for 35 years seems a bit optimistic, and resetting the timing is easy, full details are in in the service manual. Oh, and the pale green wire info above is correct - it is actually pale green and not just discoloured. But the plug V and H wiring diagram is wrong. That does not matter as long as you are consistent back to the igniter unit(s).
Here's my sensor plate with old insulation removed and new Kynar high temp shrink sleeving, plus silicone high-temperature cable. Refitting is simple enough: 1. Set the H cylinder to TDC. 2. Align the sensors with the marks on the flywheel. 3. Set the gap to 27 thou. Tighten the bolts, refit the cover, good to go.
Nice one! I had changed the coils and installed an Ignitech unit; there were so many possibilities I just connected it up and tried to start. Electric start on my bike, so a bit safer! I had got it the wrong way round, but all it did was spit back through one carb. So I switched over and all was well.
Sometimes you can save these if the wire is still ok where it leaves the pick up but if its breaking up there then i do replacements which are original magnet units re wound with about a meter of wire protruding so should get you up to the Bosch boxes without a break
HI I have taken off my pickups as the wire was completely exposed - unfortunately I mixed them up! (Dork) I should have read your post first!!! Can you tell me if it is the left hand or right hand pickup which goes to the vertical cylinder please?
