SuzukiSavage.com - Print Page

SuzukiSavage.com
/cgi-bin/YaBB.pl
General Category >> Rubber Side Down! >> Motor dies in first gear.
/cgi-bin/YaBB.pl?num=1569203433

Message started by Venturi on 09/22/19 at 18:50:33

Title: Motor dies in first gear.
Post by Venturi on 09/22/19 at 18:50:33

‘06 motor starts and idles fine in neutral but dies when I put it in gear. I have the sidestand safety wired together to bypass it. I also wired the clutch cutout to bypass it (I don’t have the harness to connect it and am just trying to get the bike going). The bike will start in neutral but dies as soon as I put it in first. I don’t think the clutch is mechanically killing the engine as the bike moves freely with the clutch pulled in and engages when released. Also, the bike is not “jerking” much when I put it in gear... it just dies. Am I missing something? Maybe bypassing the clutch safety is the issue?

Title: Re: Motor dies in first gear.
Post by Gary_in_NJ on 09/22/19 at 19:44:15

It’s not clear from your post, did you previously have the safety switches bypassed and suddenly there is a change, or did you just bypass the safeties and now you can’t get it going?

Title: Re: Motor dies in first gear.
Post by Venturi on 09/23/19 at 10:38:55

This bike has never been ridden with the current setup. This bike is a 1987, I got an ‘06 motor to replace the ‘87 and used the ‘06 wiring harness. I had to figure out some of the wiring myself as the ‘87 start/kill switch was mangled and the ‘06 didn’t come with the original. It starts up like new but dies when put into gear. While rigging up all the wiring, I bypassed the safeties as I mentioned. I will run the neutral safety to the frame today after work and see if that changes anything. Otherwise, I’m stuck for now.

Title: Re: Motor dies in first gear.
Post by batman on 09/23/19 at 11:27:42

When you bypass the clutch safety ,you tie the wires together, but not the side stand, that switch closes when the stand is down (it grounds the ignition system when the bike is placed in gear) the wires from the stand shouldn't be connected . If they are , shifting into any gear from neutral and the bike dies.

Title: Re: Motor dies in first gear.
Post by verslagen1 on 09/23/19 at 11:41:22

4B485D4448471D11290 wrote:

but not the side stand, that switch closes when the stand is down (it grounds the ignition system when the bike is placed in gear) the wires from the stand shouldn't be connected . If they are , shifting into any gear from neutral and the bike dies.

Pretty sure you got that backward BM.
The kickstand switch is open with the stand down, closed when up.

Title: Re: Motor dies in first gear.
Post by Venturi on 09/23/19 at 12:19:26

According to Clymers, the sidestand switch is closed when the stand is down and open when up. The strange thing is, the bike starts when the wires are closed and won’t start when open. Also, if I start the bike in neutral with the wires crossed (i.e. touching) and disconnect them after started... it dies...

Title: Re: Motor dies in first gear.
Post by DragBikeMike on 09/23/19 at 13:19:59

The 1987 side stand switch is different from the 2006 switch. So if you are using the 2006 harness with the 1987 switch the system may not work correctly. The 1987 model used a simple switch while the 2006 model uses a switch that incorporates a diode. Not sure if this helps. Good luck.

Title: Re: Motor dies in first gear.
Post by Serowbot on 09/23/19 at 14:59:36

Is it remotely possible that the oil is too thick or the idle too low?...

Title: Re: Motor dies in first gear.
Post by Venturi on 09/23/19 at 15:35:01

Serobot, no. I’m using Redline 10W40 Motorcycle Oil recommended on this forum and I’ve already adjusted the idle up and down to narrow down troubleshooting. I don’t think it’s mechanical at all. The engine is cutting out smoothly like it’s an electrical switch. I’m going to focus on the sidestand cutout. Does anyone know what the diode in the switch does? Can you not just short the two wires on the harness to bypass it on ‘06 and later bikes?

Title: Re: Motor dies in first gear.
Post by Serowbot on 09/23/19 at 15:40:27

My sidestand switch is jumpered at the connector under the seat.
2 wire,.. green I think...

Title: Re: Motor dies in first gear.
Post by Venturi on 09/23/19 at 16:03:44

So... I grounded the neutral switch and it goes into gear now. It wasn’t the sidestand safety at all. I’m going to see if she rides! But, does this mean the neutral safety switch (blue wire coming out of the clutch) is bad?

Title: Re: Motor dies in first gear.
Post by Venturi on 09/23/19 at 16:36:03

She rides!!! My first bike build! I’ve been riding motorcycles for about 13 years but have never broke one down and rebuilt it like this. Thanks everyone for this forum! You all are the best!

Title: Re: Motor dies in first gear.
Post by justin_o_guy2 on 09/23/19 at 16:53:49

Is the neutral light never on or always on?

Title: Re: Motor dies in first gear.
Post by Venturi on 09/23/19 at 17:34:24

Always on now. I grounded it from the harness.

Title: Re: Motor dies in first gear.
Post by justin_o_guy2 on 09/23/19 at 18:43:03

I think the sidestand switch bypass is the problem.
Haven't studied the circuit, but that's where I am now.

Title: Re: Motor dies in first gear.
Post by Venturi on 09/23/19 at 18:58:19

Well, I have all three safeties bypassed now. I don’t know why the sidestand circuit was killing it in neutral or why the neutral switch was killing it in first. I think it has to do with how the sidestand switch integrates with them? At this point it’s not worth it for me to try and pinpoint it. The bike runs smooth now.

Title: Re: Motor dies in first gear.
Post by verslagen1 on 09/23/19 at 20:02:07

457C6F623F3C360E0 wrote:

you can test the switch, ohm meter to ground and the wire. in neutral should go to zero.
it could be the diode in the harness too.