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General Category >> Rubber Side Down! >> Troubleshooting electrical starter interlock syste
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Message started by humblegeo on 07/20/14 at 07:41:38

Title: Troubleshooting electrical starter interlock syste
Post by humblegeo on 07/20/14 at 07:41:38

Wishing there was a schematic for starter interlock electrical systems. Clutch switch, kickstand switch, kickstand relay, start switch etc etc. Bike had been starting fine then I had done some work on it, had kickstand off, handlebar controls apart, tank off to replace speedometer cable, seat off odds and end, back together and now starter won't energize. Kickstand down, clutch lever pulled in, red kill switch in run position, lights come on and voltage above 12vdc. When I turn the key on, the kickstand relay energizes and stays energized even when I work the kickstand switch by hand. Shouldn't the kickstand switch turn the kickstand relay on and off? Should the kickstand relay be energized for a healthy ready to start condition or denergized for a healthy ready to start condition? Appreciate some help understanding correct operation of the electrical starter interlock system.

Title: Re: Troubleshooting electrical starter interlock s
Post by Serowbot on 07/20/14 at 08:16:07

To start with,.... you can bypass the kickstand and clutch cut-outs...
Clutch,.. at the handlebar lever, and stand...

Just disconnect and jumper the two, harness side, wires...
If that fixes it,.. you got it... if it don't you can check them off the list...

Title: Re: Troubleshooting electrical starter interlock s
Post by Steve H on 07/20/14 at 09:44:18

Wiring diagrams are here
http://suzukisavage.com/cgi-bin/YaBB.pl?num=1294779818
in the tech section. They include the safety circuits.

Title: Re: Troubleshooting electrical starter interlock s
Post by Kris01 on 07/20/14 at 10:09:50

I think I read on this forum once that those diagrams have the wrong colors. They came from the Chilton's manual and they got it wrong. I'm sure the connections are probably right but you may find that the colors don't match.

Title: Re: Troubleshooting electrical starter interlock s
Post by humblegeo on 07/20/14 at 14:15:04

Found a schematic of the safety system here in the forum posted 1/9/2010 (Electric Mysteries Investigated). Since my side stand relay is energizing, the side stand switch and neutral switch are probably working or at least completing the path to ground that is required for side stand relay operation. Side stand relay then sends the 12(+) power to the kill switch which if closed sends power on to the start switch which when pushed sends power to the clutch switch and if its closed it sends the power to decompression solenoid and starter relay. Engine should crank. I need to take some voltage readings to see where I'm missing the power at in this circuit but I'm thinking it might be at the clutch switch. Seems like many of the savage owners have just bypassed these safety interlocks and been done with it.

Title: Re: Troubleshooting electrical starter interlock s
Post by humblegeo on 07/20/14 at 16:04:35

Feel kinda stupid now. My problem was that I didn't get the clutch handle switch connector plugged in all the way. Oh well, at least I learned how the safety interlock electrical system works. ::)