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Message started by serenity3743 on 03/18/10 at 05:16:16

Title: Need help with electrics
Post by serenity3743 on 03/18/10 at 05:16:16

The weather is getting nice for riding, and I got nothing to ride! >:(

Okay, let me give some history first.  My bike is on its 3rd battery in 2 years.  They seem to get drawn down way sooner than they should.  The alternator is not original, because I did a total motor transplant about 3 years ago.  The starter, rectifier, relays, coil, all electrics (except for the wiring harness from the alternator to the rectifier) are original. I did the cam chain adjuster and new cam chain about a month or two ago. In the process, I found the three yellow wires (left side) from alternator to rectifier all had exposed copper due to damaged insulation.  I fixed those with crimp splices and electrical tape.  I also found that the blue wire (right side) from neutral switch to connector under the tank was badly frayed at the clutch cover entry point and I repaired it the same way.  

"Current" problem (pun intended):  After I finished putting it all back together, I rode it around the neighborhood some, no problems noted.  Rode it to town 5 - 10 miles several times, no problems.  One cold morning (27F) I was gonna ride it to work, went out to crank it and it turned over only weakly, not strong enough to start up, so I went to work in the car.  Tried it that evening when I got home and it cranked right up.  Last ride was about a week ago, headed to town on an errand.  Coming down the exit ramp, I noticed the thing just sputtered a little, then it totally died, felt like it just stopped firing.  I tried bump cranking it before it came to a stop, got nothing.  Came to a stop, tried to crank it with the start button, engine would turn but not fire up.  Being as I was only 3 miles from home, I called my wife and had her to bring the car and a tow rope and we hobbled it home that way.  Took battery out and charged it.  Put battery in, tried to crank, got nothing except the two heavy clicks from the automatic decompression action.  Checked spark plug, very white, but of course I can't test it for firing.  Have explored all of the wires and connectors for breaks, corrosion, etc.  Battery is probably not holding its charge, but it does the same thing when I try to jump start it.  Fuses appear good.  Lights work, horn works, turn signals and brake lights work.  Speedometer indicator lights work EXCEPT for the neutral light which would not activate after I put it all back together; I figured it was just a bulb, but now not so sure, could be something wrong at the neutral light junction under the clutch cover?

The Clymer manual details some electrical diagnostics, but most of them are done either with motor running or at least warmed up, which I am unable to do 'cause it won't fire up.

I know I'm gonna need a new battery, but don't want to install one until I find out what's drawing it down.  Any ideas of things to pursue would be greatly appreciated.  Seems like something is grounding or shorting out? or maybe the starter is shot?  If you can suggest any simple diagnostics I can try, please share.  My last resort will be to take it to a Suzuki shop I trust and see if they can diagnose it for me. 


Title: Re: Need help with electrics
Post by babyhog on 03/18/10 at 07:15:08

bad alternator maybe?

Title: Re: Need help with electrics
Post by verslagen1 on 03/18/10 at 07:38:24

with good everything except neutral lite, I'd begin there.  
But that's only a ground to turn the lite on.

Corrossion on the connectors for those yellow wires can cause battery problems, so splices there would be suspect.
But is it a battery issue?

I'd check out the starter relay.
The starter button has been an issue from time to time.  Can't hurt to clean it.

Title: Re: Need help with electrics
Post by justin_o_guy2 on 03/18/10 at 07:44:54

Are the batteries running low on H2O? If so, the regulatormay be cooking them.

Title: Re: Need help with electrics
Post by Moofed on 03/18/10 at 09:08:34


7B687F7E616C6A68633C0D0 wrote:
with good everything except neutral lite, I'd begin there.  
But that's only a ground to turn the lite on.


The Clymer wiring diagram for a 2000 shows the side stand diode between the neutral light and neutral switch.  I think it (and through it the neutral switch) is only relied upon to power the side stand relay when the sidestand is down.  Meaning it wouldn't explain the running engine cutout.

Do what verslagen said.  Might check the engine stop switch for corrosion too while you're in there.  If testing the starter relay works and the starter motor runs, then maybe the decomp controller is bad?  Not sure what else can make the decomp coil fire but not the starter motor.

3 batteries in 2 years also says something is wrong.  Maybe regulator is not regulating?

Title: Re: Need help with electrics
Post by serenity3743 on 03/18/10 at 09:08:36

All good ideas.  Can't test alternator with what I have, because IT WON'T RUN, DAMMIT!  Also, alternator came with engine, only has about 22,000 miles on it.  Can't test rectifier because (per Clymer's) a special tool/tester is required.  I'll try to check further into the neutral switch, starter switch and starter relay this evening.  J.O.G., now that you mention it, one (or maybe two) cells have needed water the last couple times I've put battery on charger, so that might be pointing to the rectifier (which, as I stated, is still the original one).  Vers., it is definitely a battery issue, but I think something else is CAUSING the battery issue.  

Thanks for the input.  I hate to take it in to the dealer since I've become more confident (and competent) in working on the bike, but I'm still reserving this option.

Title: Re: Need help with electrics
Post by verslagen1 on 03/20/10 at 00:00:50

some good stuff in here...
http://suzukisavage.com/cgi-bin/YaBB.pl?num=1099317926/15


Title: Re: Need help with electrics
Post by dasch on 03/20/10 at 00:53:23

Acts the same when you jump it? I'd disregard the battery, rectifier and alternator for a moment, until you get it to crank and start.

Check the starter. Jump it from car ground to bike ground and from car positive to STARTER TERMINAL directly (under rubber cap on the starter). Make sure you are in neutral!!!! Just check if it spins or not when under good 12V.

If starter is spinning check the starter relay. Car ground to bike ground, car positive to bike battery + and another wire from bike positive to y/b on the relay. That should bypass the ignition switch and kill/start buttons, if all good should click and engage the starter.

I'd go with these two for now. Post what happens.

Title: Re: Need help with electrics
Post by Routy on 03/20/10 at 06:27:33

Dasch has it right,.....check the basic stuff first, bypassing switches, sillynoids etc. If that works, then start adding the solenoid saftey switches etc. Use process of elimination.

If you do your own trouble shooting, work etc, you should have at minimum..........
1-  12v probe test light
2-  A hand held digital voltmeter
3-  A continuity checker w/ internal battery (could be in volt meter)

(caution, never touch a continuity tester to 12 volts)


Title: Re: Need help with electrics
Post by serenity3743 on 03/22/10 at 05:16:23

Good info from all.  I didn't have time to work on bike this weekend.  Wife said yard needed cleaning.  Will try starter and starter relay tests.  I have an auto multimeter, Routy; will that suffice?

Title: Re: Need help with electrics
Post by Routy on 03/22/10 at 06:46:57

Yes,....and most have a continuity scale in them also.

But for trouble shooting, a 12v test probe is probably used more than anything,.... much nicer for probing into wires etc, and getting into tight spots. The digital multimeter is better for technical voltage testing of batteries, and charging systems etc.



34223522292E333E74707374470 wrote:
Good info from all.  I didn't have time to work on bike this weekend.  Wife said yard needed cleaning.  Will try starter and starter relay tests.  I have an auto multimeter, Routy; will that suffice?


Title: Re: Need help with electrics
Post by serenity3743 on 03/24/10 at 16:01:15

Okay, Dasch.  The starter spins with your test as above.  But I cannot get the starter to activate through the relay wire (Y/B).  See if I did it right:  Jumper cable from car battery to Savage battery.  I pulled off the Y/B wire connector at the starter relay and inserted an 18 gauge wire, running it to the + battery connection:  nothing happens.  More advice, please?

Title: Re: Need help with electrics
Post by dasch on 03/24/10 at 19:18:11

Before I say "starter relay is dead". Let me just confirm:
car + to bike +
car ground to bike ground
bike + to relay Y/B

If that's it - then... that's it!! Relay appears stuck or burned.
Disconnect relay and check continnuity with ohm meter beetween Y/B and Black contacts. We go from there.
If there is continuity - stuck. Try lightly knocking it with a screwdriver handle a few times. Maybe that releases it - short term solution, but it might get you spinning for now.



Title: Re: Need help with electrics
Post by serenity3743 on 03/25/10 at 07:44:17

Dasch, here is the part I'm unclear about:  Do I touch the extra wire to the Y/B connecTOR, or do I touch it to the Y/B connecTION on the relay itself?  I only tried it the first way, but looking back should have tried it the second way also.

Title: Re: Need help with electrics
Post by Routy on 03/25/10 at 09:19:31

When you connect positive battery voltage to the little terminal on the starter relay, (which is what the starter button on the handlebars does)that should close (connect) the large terminals on the relay, which would in turn bring positive voltage from the battery to the starter making it spin.

Title: Re: Need help with electrics
Post by dasch on 03/25/10 at 09:37:45

Disconnect the Y/B and touch the pin on the relay itself. Be careful, that's a live + you are whipping with ;-)

Try several times, try cleaning the pin somehow first, then touch it. We (you) need to be 100% sure about the relay, before we go further.

Title: Re: Need help with electrics
Post by serenity3743 on 03/25/10 at 10:32:31

Thank you, Routy and Dasch.  I will test it out after work this evening.

Title: Re: Need help with electrics
Post by serenity3743 on 03/25/10 at 15:00:38

Okay, now that I did the test correctly, the relay activates the starter.  Next step, please?

Title: Re: Need help with electrics
Post by dasch on 03/26/10 at 02:10:30

Next step... hmmmm... all right... relay is fine, starter is fine. we will get to stupid safety systems next (clutch switch, neutral light, sidestand switch  ;)
I get my hands on the schematics tonight and give you few more.

Title: Re: Need help with electrics
Post by serenity3743 on 03/26/10 at 08:02:35


5C594B5B50380 wrote:
. . . clutch switch, neutral light, sidestand switch. . .

Dasch, I can tell you that the neutral light was not illuminating after reassembly following cam chain and adjuster replacement.  I have tested the bulb and it is good.  So I've been thinking for some time it is the neutral safety switch.  Can we start there?

Title: Re: Need help with electrics
Post by dasch on 03/26/10 at 09:08:59

If you insist so. We can cover others later. Looking at the schematics - you need to find a plain blue wire going towards the gearbox and ground it somehow. There's a quick release coupling on it somewhere. FInd it, disconnect and ground the end going towards the gas tank, not the one on gearbox side. Then test with bike jumped + to + ground to ground.
You don't need the extra wire to Y/B anymore. Connect relay as it was. Clean contacts first, while you're at it. Post what happens.

Title: Re: Need help with electrics
Post by serenity3743 on 03/26/10 at 11:23:19

The blue wire you're talking about is the one that enters the clutch cover and is soldered to the neutral switch internally, right?

Title: Re: Need help with electrics
Post by dasch on 03/26/10 at 11:27:49

Correct. And this internal switch grounds it when in neutral. So we need to ground that wire somehow faking neutral switch engaged. And then try to crank with bike jumped.

And you and I will do that with every freaking switch that effects the starter function  ;)

And then... real work!

Title: Re: Need help with electrics
Post by dasch on 03/26/10 at 12:50:58

serenity, out of my curiosity - try if it works with blue wire disconnnected as well. Please, post what happens with neutral light and starting in both cases.

Title: Re: Need help with electrics
Post by justin_o_guy2 on 03/26/10 at 14:52:07

& theres a little skinny 12 volt/red wire under the seat that can be jumped to the decomp timer & the starter will turn it over, even with the key in your pocket, no matter what gear its in, or if the clutch is pulled, or sidestand down..

Title: Re: Need help with electrics
Post by justin_o_guy2 on 03/27/10 at 18:23:55

Geeeeze, I didnt mean to kill it

Title: Re: Need help with electrics
Post by dasch on 03/27/10 at 20:57:45

:D


Title: Re: Need help with electrics
Post by serenity3743 on 03/29/10 at 05:02:48


7B7E6C7C771F0 wrote:
serenity, out of my curiosity - try if it works with blue wire disconnnected as well. Please, post what happens with neutral light and starting in both cases.

My findings are:  The starter turns the engine with switch grounded, without switch grounded, and with regular connection made.  Neutral light still does not illuminate.  So what does all that mean?  Something tells me it shouldn't really do that. :-?

Title: Re: Need help with electrics
Post by justin_o_guy2 on 03/29/10 at 05:26:43

Id make sure I had 12 V to thr N lite. Then, Id provide a ground Y& prove it WILL lite up.

Title: Re: Need help with electrics
Post by dasch on 03/29/10 at 05:41:11


5F495E49424558551F1B181F2C0 wrote:
My findings are:  The starter turns the engine with switch grounded, without switch grounded, and with regular connection made.  Neutral light still does not illuminate.  So what does all that mean?  Something tells me it shouldn't really do that. :-?


No, it shouldn't. Hmmm... something tells me... Have you ran this test with stock setup of the starter relay? I mean, without the extra wire to Y/B? And using start button to fire up? You should have. Maybe I wasn't clear.

Title: Re: Need help with electrics
Post by serenity3743 on 03/29/10 at 08:57:12


575240505B330 wrote:
[quote author=5F495E49424558551F1B181F2C0 link=1268914576/15#27 date=1269864168]My findings are:  The starter turns the engine with switch grounded, without switch grounded, and with regular connection made.  Neutral light still does not illuminate.  So what does all that mean?  Something tells me it shouldn't really do that. :-?


No, it shouldn't. Hmmm... something tells me... Have you ran this test with stock setup of the starter relay? I mean, without the extra wire to Y/B? And using start button to fire up? You should have. Maybe I wasn't clear. [/quote]
I'm not positive what your question means.  If you mean, will the bike crank over with just jumper cables from a known good battery, the answer is yes.  In my first post, I think I mentioned that all I got when I tried to crank it was the two clicks from the decomp solenoid.  But now that I'm jumping from my car battery, I get cranking action.  What I'm really needing to track down is the reason why my battery keeps getting dragged down (3rd battery in 2 years).  After I fix that problem, I'm gonna get a Big Crank battery.

Title: Re: Need help with electrics
Post by dasch on 03/29/10 at 09:14:03

No, my friend. First thing was to get you cranking and find out why it doesn't. Does the engine start now? Can you idle?
If YES - let it idle and remove ground jumper cable. Still runs?
If YES - good. Hook up voltmeter with aligator clips to battery. Take a reading.
Give gas. A little. Take a reading
Give more gas. A bit. Take a reading.
Post.

Still worried about the obvious disfunction of your neutral light diodes...

Title: Re: Need help with electrics
Post by serenity3743 on 03/29/10 at 10:30:36

Yes, first thing was to get me "cranking."  I currently have the spark plug out, the tank off, the clutch cover removed, etc.  So, to see if it turns over AND starts, I need to put that stuff back together.  I will be able to do the cranking/starting/charging test tomorrow evening.  And I really appreciate the step-by-step guidance.  

Title: Re: Need help with electrics
Post by dasch on 03/29/10 at 10:45:42

Sorry we lost time, Serenity. Well.. I assumed you jumped it first, and itstill wouldn't budge.   :-[ I'll be here. And we'll find it.

Title: Re: Need help with electrics
Post by serenity3743 on 03/29/10 at 12:58:28

I don't mind going slow if it means doing it correctly. 8-)

Title: Re: Need help with electrics
Post by justin_o_guy2 on 03/29/10 at 20:10:32


223D3B3C21261727172F3D317A480 wrote:
& theres a little skinny 12 volt/red wire under the seat that can be jumped to the decomp timer & the starter will turn it over, even with the key in your pocket, no matter what gear its in, or if the clutch is pulled, or sidestand down..




Seriously, no kidding, THIS will bypass so much of the wiring harness. If you do this & it Wont Crank, youve limited a great deal of the wiring.

Title: Re: Need help with electrics
Post by dasch on 03/29/10 at 20:31:05

JOG, it cranks already. All it took was a jump.

Title: Re: Need help with electrics
Post by justin_o_guy2 on 03/29/10 at 20:47:21

Great! I Missed that,,, doooooh.. Still, for all those "My Bike wont crank" threads..

Title: Re: Need help with electrics
Post by dasch on 03/29/10 at 23:53:37

I'll probably get rid of all that stuff. Maybe a buzzer of some sort to warn about the side stand, and that's it. Hell, if it's in gear, and I attempt to start it - so what? Where's it gonna go before I release the button?

Title: Re: Need help with electrics
Post by serenity3743 on 03/30/10 at 17:24:21

Dasch (and whoever else is interested), I did a minimal reassembly and tried to jump-start the bike.  Still no neutral light.  It cranked over and was getting gas, but would not start.  I pulled the spark plug, re-inserted it into the plug wire boot, and rested the plug on the engine.  There was no spark.  I tried another spark plug (which was working when I last replaced it) - still no spark.  I'm thinking this ought to get your mental wheels turning 8-).  I probably need to check the coil, huh?  But I need good advice on how to do this.

Title: Re: Need help with electrics
Post by justin_o_guy2 on 03/31/10 at 06:06:57

First, make sure youve got a hot wire on the coil

Title: Re: Need help with electrics
Post by dasch on 03/31/10 at 08:23:13

Yup. Contact on, make sure you are in neutral (disregard the light for now, try pushing the bike to confirm), kill switch to RUN, sidestand UP, and measure voltage between Orange/White on the coil and good ground. You should read battery voltage there, by the schematics.

Title: Re: Need help with electrics
Post by serenity3743 on 03/31/10 at 08:45:35

It might be Friday before I can test the coil.  You guys are awesome! 8-)

Title: Re: Need help with electrics
Post by dasch on 03/31/10 at 09:59:48

C'mon now... If we were awesome, you'd be on the road by now!  ;)

It's a payback, serenity... many on this forum were here for me too, so... we're just... here.

Title: Re: Need help with electrics
Post by serenity3743 on 04/05/10 at 05:14:01


7E7B6979721A0 wrote:
Yup. Contact on, make sure you are in neutral (disregard the light for now, try pushing the bike to confirm), kill switch to RUN, sidestand UP, and measure voltage between Orange/White on the coil and good ground. You should read battery voltage there, by the schematics.

Here are the findings from the weekend.  With jumper cables from car battery to motorcycle battery, voltage reading at the battery terminals was exactly 12.25.  Voltage reading at the coil (+ to O/W, - to head) was not exact:  fluctuating between 11.15 and 11.22 at first.  After 2 or 3 minutes, the fluctuation had dropped to 11.12 to 11.15.  Your interpretations, please? :-?

Title: Re: Need help with electrics
Post by justin_o_guy2 on 04/05/10 at 06:21:00

Id`start by cleaning the battery cables up & any grounds along the way.
If you can clip the leads on & wiggle stuff,, well, you know.

Title: Re: Need help with electrics
Post by serenity3743 on 04/05/10 at 09:00:56


56494F4855526353635B49450E3C0 wrote:
Id`start by cleaning the battery cables up & any grounds along the way.
If you can clip the leads on & wiggle stuff,, well, you know.

Huh?  Oh, I guess you mean attach the leads and see if the reading varies when I move stuff around?  Okay, I'll be trying that today or tomorrow.

Title: Re: Need help with electrics
Post by dasch on 04/05/10 at 10:27:52

Oh boy, 1 volt drop just by sitting still. More when you crank/run. There's only three places on the + side: Battery +, ignition lock connector and kill switch.
On the ground side... good luck. I hate loose grounds on cars, not fun to find and cause weird s**t.
Take it easy and do what Justin said. Cover every connector you find, clean it, tighten, whatever it takes. It can't hurt while you're at it.

Title: Re: Need help with electrics
Post by serenity3743 on 04/12/10 at 08:17:53

Still trying stuff.  I'm getting 12.48v as a reading at the battery and at the junction near the ignition key.  I'm getting 11.00v and below at the coil.  Also, I disconnected the coil and still got the same reading (11.00 and below) at the orange wire end.  I've started unwrapping the tape from around the wiring harness.  I found a fuse near the coil, tested it and got the 11.00v and below reading.  I think this means my problem is somewhere between the ignition and the coil.  Any other ideas or input?

Title: Re: Need help with electrics
Post by dasch on 04/12/10 at 09:18:30

Ignition lock connector and kill switch. That's what you have left on the + path to the coil. Check voltage between ground and those points.

Title: Re: Need help with electrics
Post by dasch on 04/12/10 at 10:47:11

Or we cut this short. Run a separate wire from bat + straight to the O/W on the coil. You can leave it connected, just stick it in somehow. Than try.

Title: Re: Need help with electrics
Post by serenity3743 on 04/13/10 at 05:27:08


272230202B430 wrote:
Ignition lock connector .  .  .

I think this is what I referred to as "junction near the ignition key."  Also, can you tell me specifically how to test the kill switch?  And I will also try the short-cut you mentioned in your last post.  Thanks.

Title: Re: Need help with electrics
Post by dasch on 04/13/10 at 22:39:48

Well, acccording to clymer there's several different wire color combinations for different production years. Can't guarantee which to short, however, you can always dissasemble the right hand grip, get to kill switch from behind and short it's two wires wherever it's convenient. Or use a street punk method and run a sharp steel needle through both to connect. When done remove needle and wrap some tape over holes.

Title: Re: Need help with electrics
Post by serenity3743 on 04/30/10 at 05:12:46

Okay, I've tried every test I know to try.  Still no fire at the sparkplug.  Voltage is getting to the kill switch, the coil, the ignition, etc.  I think I'm gonna try replacing the coil.  Any other ideas short of that?

Title: Re: Need help with electrics
Post by ratz on 04/30/10 at 05:25:27

If I'm not mistaken,the CDI makes and breaks the ground side just like points used to do.Put your meter on both of the positive and negative leads of the coil and see if it pulses as you crank the engine.If not,the CDI may be at fault,or the pulse coil that feeds the CDI may be bad.
You can check the resistance value of the pulse coil,or disconnect it,put your meter leads on it,and check for a pulse at cranking.Keep in mind,though,that this will be a very small voltage,so you will need to be on the lowest voltage range of the meter for checking the pulse coil.

Title: Re: Need help with electrics
Post by dasch on 04/30/10 at 08:13:34

Oh, I got some ideas... all bad. Do what ratz said, for start. Check ohm reading of the disconnected coil.

You know... mine wouldn't start once, and it was because of the loose connection on the CDI. Everything looked tight, but one of the wires was still loose. I had to rattle each one separately while a friend was cranking, to find it...

Title: Re: Need help with electrics
Post by dasch on 05/01/10 at 02:11:18

Numbers from Clymer:
1-7 Ohms on primary of spark coil.
10-25KOhms on the secondary.
200-240 Ohms on the signal generator (between Green and Orange).

Assuming you already done all test shortcuts in previous posts, and all of these Ohm readings are ok, you either have a bad connection that you missed somehow (most likely), or your CDI is dead (possible).

Title: Re: Need help with electrics
Post by serenity3743 on 05/27/10 at 05:14:19

It's been a long haul, but I got her back on the road last evening.  Here's a summary of my findings, with no definitive root cause as yet.  I tried all the testing on the wiring.  Finally found that the plug wasn't firing.  And, SURPRISE, the next time I tried it the plug WAS firing!  I got the wiring harness from Sakara and was gonna try that, but it wasn't necessary.  Last weekend I discovered that the main wire bundle, rear of where the headlight wiring branches off, had an issue:  While the bike was running, when I pulled it forward or pushed it in under the tank, the bike would die.  I think I had routed it wrong at some point in the past.  Re-routing it with plenty of slack, and on top of the tank support "ears", fixed the problem.  I rode to work today with everything working just right.  

Thanks for the help.  Just wanted to bring the thing full circle to a conclusion.

Title: Re: Need help with electrics
Post by babyhog on 05/27/10 at 08:09:12


5B4D5A4D46415C511B1F1C1B280 wrote:
It's been a long haul, but I got her back on the road last evening.  Here's a summary of my findings, with no definitive root cause as yet.  I tried all the testing on the wiring.  Finally found that the plug wasn't firing.  And, SURPRISE, the next time I tried it the plug WAS firing!  I got the wiring harness from Sakara and was gonna try that, but it wasn't necessary.  Last weekend I discovered that the main wire bundle, rear of where the headlight wiring branches off, had an issue:  While the bike was running, when I pulled it forward or pushed it in under the tank, the bike would die.  I think I had routed it wrong at some point in the past.  Re-routing it with plenty of slack, and on top of the tank support "ears", fixed the problem.  I rode to work today with everything working just right.  

Thanks for the help.  Just wanted to bring the thing full circle to a conclusion.


Geez, you been workin on that thang forever!  LOL   ;D

Really, glad you are up and running, and good to see you back online.  I thought you got pissed at the bike and ran off on us too!   I missed you....   8-) 

Title: Re: Need help with electrics
Post by verslagen1 on 05/27/10 at 08:23:30


697F687F74736E63292D2E291A0 wrote:
Last weekend I discovered that the main wire bundle, rear of where the headlight wiring branches off, had an issue:  While the bike was running, when I pulled it forward or pushed it in under the tank, the bike would die.  I think I had routed it wrong at some point in the past.  Re-routing it with plenty of slack, and on top of the tank support "ears", fixed the problem.  I rode to work today with everything working just right.  

So it has a problem, but you fixed it by tugging on the wire and then tieing it down where it worked.  Seems to me that either you have a loose connector or a broken wire.  Sure, I'd ride it but I'd carry what I'd need to fix it at all times.

Title: Re: Need help with electrics
Post by dasch on 05/27/10 at 08:29:30

:) glad it runs!

But you really should find the exact problem, now that you know where to look, it shouldn't be hard.

Title: Re: Need help with electrics
Post by justin_o_guy2 on 05/27/10 at 08:44:19

He may just be sick of messing w/ it.. I know I would be, after the hassle hes been thru. Just tickled to ride.
May you not have to walk home.

Title: Re: Need help with electrics
Post by serenity3743 on 05/27/10 at 08:54:26


6162636E6C760F0 wrote:
[quote author=5B4D5A4D46415C511B1F1C1B280 link=1268914576/45#57 date=1274962459]It's been a long haul, but I got her back on the road last evening.  Here's a summary of my findings, with no definitive root cause as yet.  I tried all the testing on the wiring.  Finally found that the plug wasn't firing.  And, SURPRISE, the next time I tried it the plug WAS firing!  I got the wiring harness from Sakara and was gonna try that, but it wasn't necessary.  Last weekend I discovered that the main wire bundle, rear of where the headlight wiring branches off, had an issue:  While the bike was running, when I pulled it forward or pushed it in under the tank, the bike would die.  I think I had routed it wrong at some point in the past.  Re-routing it with plenty of slack, and on top of the tank support "ears", fixed the problem.  I rode to work today with everything working just right.  

Thanks for the help.  Just wanted to bring the thing full circle to a conclusion.


Geez, you been workin on that thang forever!  LOL   ;D
I KNOW -- RIGHT??

Really, glad you are up and running, and good to see you back online.  I thought you got pissed at the bike and ran off on us too!   I missed you....   8-) [/quote]
YOU MISSED ME!  YOU REALLY MISSED ME!  I think we established that this was a Sally Field quote (now paraphrased by me).  But, did ya really notice I was gone for awhile?

Title: Re: Need help with electrics
Post by dasch on 05/27/10 at 08:56:17

Hehehe. Keep the spirit!!

Title: Re: Need help with electrics
Post by serenity3743 on 05/27/10 at 08:57:11

I know.  I've got to find the root cause.  But you're right, JOG, I'm just glad to be riding.  And I've got my tools in the saddlebag.  The weather sure is pretty here!!!!!!!!1

Title: Re: Need help with electrics
Post by babyhog on 05/27/10 at 09:14:56

Of course I noticed you hadn't been around!  You are usually signed in when I get to work and sign in myself.  Remember, I'm a detail person.  I was about to ask Oldfeller where you were hiding, just cuz I'm nozy.  

So... where the heck have you been anyway?  If'n ya don't mind my askin'  

Title: Re: Need help with electrics
Post by serenity3743 on 05/27/10 at 10:25:48

I've been around, just not on here.  Mowing, mulling over electric probs, reading, mowing, tilling, and did I mention mowing?  Plus more to do at work.

Title: Re: Need help with electrics
Post by serenity3743 on 06/08/10 at 05:04:36

I tracked every wire and can't find where the problem is.  It's been running fine and I'm just glad to be back on the road, albeit with extra tools in my saddlebag, just in case!  Planning on doing the Dragon ride later this month!

Title: Re: Need help with electrics
Post by justin_o_guy2 on 06/08/10 at 07:06:15

I had an electrical issue I never found. It went away,, I stopped looking..

Title: Re: Need help with electrics
Post by kimchris1 on 06/08/10 at 11:31:29

Serenity, I do hope that somehow your problem got fixed. I just finished reading all the posts concerning your problem.
Hell I feel like I read a good book. I say good as it came out with a happy ending. You back in the saddle.

I wish you all the best.. Congratulations on staying with it and not giving up... Kim

Title: Re: Need help with electrics
Post by DaveLKN on 06/08/10 at 19:52:47

I feel like I just read a mystery novel as well- spellbinding.
I know where I'm headed if I have such a problem with my '98-
across Lake Norman....

And- I am very impressed with the help and patience of all involved here.  Kudos to all.

Dave

Title: Re: Need help with electrics
Post by serenity3743 on 06/09/10 at 11:59:24

I didn't know we were co-authoring a mystery-thriller! :D  

Welcome, DaveLKN  !   You will find a lot of help here if you're a Savage/S40 rider (or even if you're not!)  Is LKN for Lincoln County?   If you're at Lake Norman, we're not far apart at all.  Hope to meet you soon!  Do ya know about the Suzuki Savage camping trip this month?

Title: Re: Need help with electrics
Post by DaveLKN on 06/26/10 at 20:21:05

By the time you read this you'll have gone to the Dragon and back, I'm sure.  Hope you guys have had a good time.

I've got a 98 Savage that I just got back on the road yesterday.  Not enuf experience with it to launch a trip out very far yet.  I'm also working on a 98 Marauder that has been sitting for a few years...the tank on down to the carbs has been redone- just got to finish the carbs (there's two, they're different, and they're a pain to work on...so guess which bike gets going first....the Savage).

LKN is the local abbrev for Lake Norman.  You're just across the lake from me.  I'm very close to Stumpy Creek Landing and Lake Norman Airpark and work in Troutman.  I go thru Catawba once in a while enroute to Hickory up Buffalo Shoals Road.  It would be cool to meet up with other Suzuki owners in this area that work on their own stuff.  How 'bout it?

Title: Re: Need help with electrics
Post by serenity3743 on 06/28/10 at 13:04:25

Yeah, I'm up for that.  And there's other guys in the general area:  Toymaker in Lenoir, Midnightrider in Winston-Salem, BIGZUK in Asheville.  BTW, I don't live in Catawba, NC; I put (Catawba) on my profile to differentiate from another Hickory, NC, which is in one of the far eastern counties.  I'll try to change that to avoid confusion.

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