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Message started by danman1 on 09/08/11 at 11:49:28

Title: electrical problems
Post by danman1 on 09/08/11 at 11:49:28

my 1995 suzuki sl650 wont fire up. i bought a new wire harness due to my original one being in very bad condition, and the plastic connectors for the right and left handlebar switches are all wrong. can i cut and connect the wires and make it work?. all the wires are there. just cant get it to turn over.

dan :-?

Title: Re: electrical problems
Post by Serowbot on 09/08/11 at 11:53:54

You're going to have to find someone local to help with that...

No way we could know what's connected to what and where...

What year is your harness from?... any idea?... :-?...

Title: Re: electrical problems
Post by justin_o_guy2 on 09/08/11 at 11:54:33

Or you can steal connectors off the old harness,, but yea, you can hook straight in,

You Can slip the pins out of the connectors & swap the plastic housings that make the connectors & not even cut a wire. Need a jewelers screwdriver to pop the catches loose,

Title: Re: electrical problems
Post by verslagen1 on 09/08/11 at 11:56:25

No need to cut, the connectors can be pulled out with a tool.

Are you sure you bought the right year? or bike?

Don't think there's any connector changes from 88 up to 02.

Title: Re: electrical problems
Post by danman1 on 09/08/11 at 12:19:26

im in oxnard , ca........ill find out what exact year from the sticker on the harness.. i thought maybe i can just pop the wires out of the plastic connector at first and save the individual tips but the wire tips for the new harness are all female and the stock wire tips from the handlebars switches are all female. so thats a no go. see the pics?
http://i28.photobucket.com/albums/c206/keepfighting/savage/IMG_0111.jpg
http://i28.photobucket.com/albums/c206/keepfighting/savage/IMG_0110.jpg

Title: Re: electrical problems
Post by danman1 on 09/08/11 at 12:28:00

its a 2005 harness. i ordered off ebay for cheap . listed as 1995.
so now my question is can i get it to work? im electronically challenged sometimes. i seen some posts about simplified harnesses for chopper??? i would appreciate any help. walkthroughs?

Title: Re: electrical problems
Post by danman1 on 09/08/11 at 12:36:39

all i want to run is

headlight hi/low
brake light- front and rear brake
neutral indicator light.
i also would like to start the bike.

any help is appreciated!

Title: Re: electrical problems
Post by drums1 on 09/08/11 at 14:34:04

From your 1st pic, where one connector has 10 pins and the other one has 7......I'd have to say you got the wrong harness there. I'd check back with the guy on EBay.

Title: Re: electrical problems
Post by danman1 on 09/08/11 at 16:29:49

got it to start....

how can i hard wire headlight to harness?

colored wires from headlight
yellow/ black /white

Title: Re: electrical problems
Post by Boule’tard on 09/08/11 at 17:59:48

In case you did not see the wiring diagrams yet, they are here:
http://suzukisavage.com/cgi-bin/YaBB.pl?num=1294779818

It should be a cinch to get the headlight wired up. Congrats on getting it running.

Title: Re: electrical problems
Post by danman1 on 09/08/11 at 19:33:46

thanks!!! even if you didnt specifically tell me what to do. it required some thinking but after i removed the high beam, low beam switch i had to run the headlight wire to the ignition side of the bars to get its power. added a fuse for the headlight too. got the idea for the fuse from the simplified harness pic.

by connecting 2 headlight wires to the power source i got it to become very bright but it quickly blew the 20a fuse. so i added the inline 10a fuse and removed the one wire that made the headlight brightest from the mix and it worked but was not as bright.
can i put a stronger fuse and use both headlight wires to make it brighter without blowing fuses??? i currently have an inline 10amp fuse for the headlight.

sorry if this doesnt make sense.

Title: Re: electrical problems
Post by Boule’tard on 09/09/11 at 06:37:27

Check the bulb wattage and make it isn't one of those 100+W kind. Check for corrosion or other crud in the headlight socket and make sure it is not shorting out.

Try leaving the headlight wires "open" and check the high beam switch, kill switch, etc. Nothing should blow with the switches in any position.

Make sure nothing else is shorting out or drawing high amperage which would cause the headlight to look like the problem by sending the fuse over the edge.

I would not try alternative wiring to get extra brightness. It should be yellow wire to high beam filament, white wire to low beam filament, B/W to ground.

A 20A fuse should handle 240W total. An additional 10A fuse will not add capacity to your circuit, it will just blow first.

Title: Re: electrical problems
Post by danman1 on 09/10/11 at 01:58:47

makes sense. i left the 10a inline fuse anyway but i am only running high beam i guess.im pretty sure the "extra bright" setting i got for a second was just wrong all together, way to much heat emitted from the bulb.

so now im using high beam all the time, it works for me. most my riding is in the day so i prefer high beam all the time.

thanks. bike runs great. still working on its looks though.
http://i28.photobucket.com/albums/c206/keepfighting/savage/IMG_0094.jpg

Title: Re: electrical problems
Post by justin_o_guy2 on 09/10/11 at 07:10:39

im pretty sure the "extra bright" setting i got for a second was just wrong all together, way to much heat emitted from the bulb.

Both filaments on? Maybe?

Title: Re: electrical problems
Post by danman1 on 09/10/11 at 09:06:06

^yeah. it had to be.

Title: Re: electrical problems
Post by ohio thumper on 09/10/11 at 09:19:58

bike is lookin sweet dude. hows that seat feel with no padding?

Title: Re: electrical problems
Post by danman1 on 09/24/11 at 02:32:49

feels ok. i just havent had time to work on my seat but it should have atleast an inch of padding when its done. :D