SuzukiSavage.com /cgi-bin/YaBB.pl General Category >> Rubber Side Down! >> Understanding the 2007+ Wiring Diagram /cgi-bin/YaBB.pl?num=1701676461 Message started by Surviving Philly on 12/03/23 at 23:54:19

Title: Understanding the 2007+ Wiring Diagram Post by Surviving Philly on 12/03/23 at 23:54:19 Yo Savages, I'm switching out my right hand controls for a simple SPDT switch and momentary button (not running the hazard lights). While reviewing wiring diagrams and trying to design this mod, I noticed that the most late model year of the savage has different wiring for the RH switches. As you can see from this image, The starter switch receives 4 wires, as opposed to only 2 on previous model years. The switch for the start button is unchanged. What is the deal with these other two wires??  I'm trying to figure out what the two extra wires are and what I can do with them if I want to put on this simple toggle. The switch I'm trying to mount is this one -- trying to use the hi/low toggle as the starter switch and the horn button as the starter. https://www.lowbrowcustoms.com/collections/motorcycle-switches/products/cycle-standard-universal-handlebar-mounted-chrome-dimmer-switch-and-horn-button-lucas-style Thanks guys

Title: Re: Understanding the 2007+ Wiring Diagram Post by Surviving Philly on 12/03/23 at 23:54:48 Also here is the full diagram:

Title: Re: Understanding the 2007+ Wiring Diagram Post by Dave on 12/04/23 at 03:48:22 The later bikes turn off the headlight when the starter button is pushed. If you just splice the y/w and O wires together your headlight will stay on when you hit the starter button......just like the earlier bikes.

Title: Re: Understanding the 2007+ Wiring Diagram Post by Surviving Philly on 12/04/23 at 07:59:37 Interesting thanks alot vers. Wonder why they made that change.

Title: Re: Understanding the 2007+ Wiring Diagram Post by Surviving Philly on 12/05/23 at 21:10:02 Before I spend money on a clamp meter... Does anyone know what the amperage running through the kill switch and start button? I'm assuming its pretty minimal but want to make sure, I'm considering some switches that have maximum capacities of between 4-6 amps.

Title: Re: Understanding the 2007+ Wiring Diagram Post by Dave on 12/06/23 at 03:38:32 I am not Versy......I am Dave. The power running through the starter switch just turns on the starter relay.....it has to do that in order to keep the power through the switch small. The engine stop switch power is running through the side stand relay - so once again the power needed is small.

Title: Re: Understanding the 2007+ Wiring Diagram Post by Surviving Philly on 12/06/23 at 06:42:02 haha sorry dave my dyslexia is working overtime these days  ;D must be all the head injuries. I may update this thread with the wiring mods once I get things bolted up -- the world of aftermarket switches is full of Chinese trickery and subterfuge, trying to track down some cheap, minimal and ergonomic options.

Title: Re: Understanding the 2007+ Wiring Diagram Post by SpamyToo on 12/07/23 at 08:01:16 There are way less options for 1" bars.  If you go with 7/8" bars the options open up.  But that entails either a lot of changes or spacers.

Title: Re: Understanding the 2007+ Wiring Diagram Post by Surviving Philly on 12/11/23 at 10:47:31 Update here -- Before mocking up, I've decided I'm removing the decomp solenoid -- I know this can be accomplished simply by pulling it at the connection. But what about the relay? I'm assuming this relay manages power to the starter switch and therefore if it's removed, an equivalent relay would need to be installed so that the switches don't get burnt out. Is this correct? Or is it possible to just splice power from the starter relay to the clutch lever position sensor?

Title: Re: Understanding the 2007+ Wiring Diagram Post by Dave on 12/11/23 at 17:02:26 Here is a link to the information you seek! http://suzukisavage.com/cgi-bin/YaBB.pl?num=1327512118/5

Title: Re: Understanding the 2007+ Wiring Diagram Post by Surviving Philly on 12/11/23 at 19:34:28 Dave thank you so much I couldn't find this thread before you posted it. Huge help seriously.

Title: Re: Understanding the 2007+ Wiring Diagram Post by Surviving Philly on 12/14/23 at 20:41:07 Regarding decompression: Some delete the solenoid and install a manual lever, it looks like some people just don't delete the solenoid and don't do anything at all. Is there a consensus on damage due to not using the decomp? Would this kick back if starting at TDC compression and break starter teeth?

Title: Re: Understanding the 2007+ Wiring Diagram Post by Dave on 12/15/23 at 03:36:07 The damage to the starter teeth and engine case on the early bikes without the torque limiter does not happen during the starting process - it happens when shutting the bike down,  There have been a few times I have turned my bike off and as the engine comes to a stop it comes up against the compression - and I hear a strange sound as the piston kicks backward and the torque limiter engages and slips to relieve the force. What happens at startup without the automatic compression release is that most times the engine will turn over just fine when you hit the starter button and fire right up (with a good battery in warm weather).  Every so often the engine stopped on the compression stroke when you last shut it down, and when you hit the starter button the starter cannot get it pushed over TDC and stalls.  When this happens you can release the starter button -then wait a brief moment and hit the starter button again (once or twice) - and it will go past TDC and start normally. I have a manual compression release and most times I don't need to use it - and I have a Wiseco 95mm with 9.2:1 compression (stock is 8.5:1).  When it really does come in handy is if you happen to stall the bike in traffic and need to restart the bike immediately without any delay - then a handlebar mounted compression release is very convenient!

Title: Re: Understanding the 2007+ Wiring Diagram Post by Surviving Philly on 12/18/23 at 22:42:12 Taking a look at the headlight wiring -- the left front turn signal appears to have two grounds -- one ground, the white/black and then another solid black that looks like it connects to ground. What gives?

Title: Re: Understanding the 2007+ Wiring Diagram Post by Dave on 12/19/23 at 03:29:54 For Suzuki black is not always ground.  The solid black wire is the turn signal.  The black with the white is the ground.  The grey is the running light.

Title: Re: Understanding the 2007+ Wiring Diagram Post by Surviving Philly on 12/19/23 at 04:07:21 I think my confusion is that the solid black looks like it is connected to that black/white ground at the connection immediately below the signal on the diagram. Do you know why that is Dave?

Title: Re: Understanding the 2007+ Wiring Diagram Post by Dave on 12/19/23 at 17:53:12 It appears the artist who made the diagram made a mistake. The black/white and black wire got reversed on the upper side of the connector (black rectangle) to the right turn signal.  The center black/white wire coming out of the turn signal in the diagram is the ground.....it appears the black power wire for the right turn signal and the black/white ground for the left turn signal got reversed in the diagram one you get above the black rectangle connector symbols. Follow the wires below the rectangles and you can see the black and green wires go to the turn signal switch, and the black/white wires go to the negative terminal on the battery.

Title: Re: Understanding the 2007+ Wiring Diagram Post by Surviving Philly on 12/19/23 at 18:09:01 That's what I was thinking!!!!!! Sick! Thanks Dave makes sense now.

Title: Re: Understanding the 2007+ Wiring Diagram Post by Surviving Philly on 12/19/23 at 18:54:47 Wait a min. Could this actually be the error? I think that solid black wire if you follow it functions as a ground as well, it connects to the turn signal indicator the left rear turn signal and the hazard switch and the turn signal switch. There is no icon on the diagram for where it actually grounds out. But check this picture out. I think the error is that the solid black coming from the left front turn signal that turns into a white/black on that diagram is actually supposed to connect to the red/black for the horn where ive circled it on the picture. What do you think? I suppose I won't know until I actually go in there and open it up.

Title: Re: Understanding the 2007+ Wiring Diagram Post by Dave on 12/20/23 at 03:03:37 The red/black wire for the horn has power to it - when you push the horn button is grounds the horn wire......the turn signal should not be connected to that wire. Move your red circle straight up to the other side of the black rectangle....the black/white and black wire are reversed in this location. The blue wire that comes from the turn signal flasher has power to it - the power comes from the brown wire that is the running light circuit.  From the turn signal switch you can follow the green wire for the right turn signal, and the black wire for the left turn signal.....those colors should stay intact all the way to the turn signal socket. I believe the diagram should look like the image below.  This keeps the right turn signal wires together at the connector.....and also the left turn signal wires at the connector.  It also provides the black/white ground wire to enter at the center of the turn signal graphic that is consistent with the rear turn signals as well.....the rears are only different because they don't have running lights.  (Sorry about the quality....I am a better mechanic than I am a graphic artist).

Title: Re: Understanding the 2007+ Wiring Diagram Post by Surviving Philly on 12/20/23 at 03:59:08 I see now I get it -- if it were connected to the red/ black it wouldn't be connected to the flasher relay and would be hot at all times, and the black is not a ground. I've found actually a second error I think -- if you follow the solid black up to the indicator lights under the speedo they have the solid black as a ground for one of those when it should not be. But this all makes sense now thanks Dave

Title: Re: Understanding the 2007+ Wiring Diagram Post by Dave on 12/20/23 at 06:27:01 I think the turn signal indicator diagram is OK. There is only a single indicator light that works for both the left and right signals.  To allow this to happen - the little light uses the turn signal circuit for the other side as the ground. So.....you turn the right signal on, and power goes to the signal indicator through the green wire.....then it uses the black wire as a ground by sending the current to the front and rear left signals.  The amount of current required by the indicator light is so small it doesn't cause the front/rear turn signals filaments to glow. The opposite happens when you turn on the left turn signal.  The power goes to the indicator light through the black wire, and the green wire sends the current to the front and rear right turn signal bulbs - but once again they don't glow as the current is too small to get them powered up.

Title: Re: Understanding the 2007+ Wiring Diagram Post by Surviving Philly on 12/20/23 at 07:17:56 Interesting... Man what a lot to learn here about wiring and electricity in general, would absolutely not have been able to figure that out on my own. Really appreciated Dave

Title: Re: Understanding the 2007+ Wiring Diagram Post by Surviving Philly on 12/25/23 at 11:51:25 Alright, here's my mock up for the new control switches/ bar. Not perfect but I think I did OK, was my first time running wiring through bars/ drilling into bars etc. silicone behind the switch housing to compensate for a very small gap. Hoping the switches hold up, well see I guess kind of at the point of no return on this project.

Title: Re: Understanding the 2007+ Wiring Diagram Post by Surviving Philly on 12/26/23 at 22:34:24 Made a minimal wiring mock up, would anyone mind giving  me a second set of eyes on this? I think it should work.

Title: Re: Understanding the 2007+ Wiring Diagram Post by Dave on 12/27/23 at 03:20:02 I don't believe the black wire for the headlight (ground) needs to pass through the headlight dimmer switch. No horn or turn signals? :-?  (Both of those are required to be road legal where I live.....without those you are likely to get pulled over at some point).

Title: Re: Understanding the 2007+ Wiring Diagram Post by verslagen1 on 12/27/23 at 09:16:44 Hmmm, learn something every day. the decomp controller has it's own fuse. I would recommend pulling the fuses when winterizing the bike. This would prevent the self starting failure from sending your bike into the wall over the winter... if you're not going to pull the battery of course.

Title: Re: Understanding the 2007+ Wiring Diagram Post by Surviving Philly on 12/27/23 at 10:33:02 Vers that failure is caused by the decomp controller getting stuck, right? If I pull the controller like in the diagram mockup I made above it shouldn't be possible anymore is my thinking, what do you think? Dave, what are horns and turn signals?

Title: Re: Understanding the 2007+ Wiring Diagram Post by verslagen1 on 12/27/23 at 10:46:26 my comment was meant for a stock bike. no controller, no problem.

Title: Re: Understanding the 2007+ Wiring Diagram Post by Surviving Philly on 12/27/23 at 21:14:09 Alright, I'm basically finished with how I want to tackle this wiring -- the one issue that is sticking out to me is the dimmer switch/ highbeam/lowbeam switch. Is this a SPDT type switch? either high or low are on at all times? when the highbeam is on, is the lowbeam off? if so, I'm planning on replacing it with a mini toggle switch on the back of the headlight, where I'm also putting my neutral indicator light.

Title: Re: Understanding the 2007+ Wiring Diagram Post by ThumperPaul on 12/28/23 at 07:58:21 Cool bars.  Would you call them "Z" bars?  Nice work!

Title: Re: Understanding the 2007+ Wiring Diagram Post by Surviving Philly on 12/28/23 at 08:34:20 Hey thumper, Yeah they are Z bars -- Christmas gift from the misses. I'm pretty much modifying the entire bike, fenders, wiring, switches, etc. I'm going to post my final wiring diagram here for anyone who may be interested -- on this diagram, pink dots indicate where I am cutting and capping existing wires, purple lines are splices between wires, and red lines are where I am removing the stock quick connects in favor of water proof quick connects I picked up from amazon. This build will not run the horn or front turn signals, as I have not run those for about two years in near daily use. I may scrap the turn signals all together over time, we'll see. I honestly doubt anyone notices them anyway to be frank. I'll eventually post the entire build at some point in it's own thread.

Title: Re: Understanding the 2007+ Wiring Diagram Post by ThumperPaul on 12/28/23 at 16:23:30 The misses did good!  You are very ambitious!  I hate all wiring and electrical stuff! Yeah, nobody pays attention to turn signals unless you forget to turn them off.  Then they feel compelled to roll down their window and kindly let you know.  I wouldn't have a problem deleting them except for needing to pass the annual safety inspection. You're making great progress!  Git 'er dun!!

Title: Re: Understanding the 2007+ Wiring Diagram Post by Surviving Philly on 12/29/23 at 20:48:58 Ight what the crappity smack? I'm doing my thing with the wiring harness, cutting capping and splicing-- turns out the diagram is wrong. Here is a picture of the ignition connection for my 2013. Bros what the crappity smack is this double wire in here???

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