SuzukiSavage.com - Melted Electrical System

vroom1776

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Melted Electrical System
06/20/06 at 09:12:19

So there's a reason my little doo-dad guy off on the right says "S4B: I'm an idiot"

This weekend the proof was I let my best friend Jes convince me to give her a ride on my savage. Many of you know that I don't really have a seat or suspension. Well, we were doing fine until this one bump. Smashed the tail light and shorted the electrical system. I got nothing now but a charged battery.

So, I checked the battery, 12.5V, plenty of juice there. Nothing on the darn bike works. No headlight, no neutral light... nada. I have not checked the fuses yet, but the wiring diagram shows them protecting the starter motor or relay, NOT THE DARN RECTIFIER OR IGNITOR!

So, looking at the wiring diagram, and based ont he fact that the neutral light is out and wired into one of the hot rectifier leads, I am going to guess that my rectifier is melted. for starters. Gonna yank it tonight and test it. Gonna yank the ignitor and bring it down to the Suz. dealership and have them test it.

Any other suggestions?

Thanks gang!

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Dragon King Senior Member Offline Posts: 400 IL Gender:	Re: Melted Electrical System Reply #1 - 06/20/06 at 09:18:24 not sure if you can use any of this but http://cgi.ebay.com/ebaymotors/1987-SUZUKI-SAVAGE-LS650-WIRING-HARNESS-PLUS-E...
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vroom1776 Serious Thumper Offline Posts: 2110 Gender:	Re: Melted Electrical System Reply #2 - 06/20/06 at 09:25:08 thanks dk. Bid on that and another rectifier. Just hoep I don't need an ignitor. V
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Keith_B Ex Member	Re: Melted Electrical System Reply #3 - 06/20/06 at 12:39:05 Check the main fuss!
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thumperclone Serious Thumper Alliance Member Offline PGR rider riding with respect Posts: 6142 Grand Junction Colorado Gender:	Re: Melted Electrical System Reply #4 - 06/20/06 at 14:13:23 Keith_B wrote on 12/31/69 at 16:00:06: Check the main fuss! hopfulyy its the fuses..insure you repair all nicks and cut in the wires insulation..good luck!!
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short round

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Re: Melted Electrical System
Reply #5 - 06/20/06 at 22:09:19

Certainly check the fuses first. Start with the simple and work forward. On mine, a connector under the tank came loose (half in half out) and when I hit a bump it would die and blow a fuse. Put in a fuse and it was fine till I hit another bump. I just pushed the connector all the way in and it was fixed. Only problem was I dented my tank when I dropped it taking it off!!! It's always something. Hope this helps and it's just a fuse or loose connector.

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Ron
South Central Missouri

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Violent_Rage Senior Member Offline Burp! Posts: 282 Trento - Italy Gender:	Re: Melted Electrical System Reply #6 - 06/21/06 at 00:31:24 i've found a melted wire too... I've replaced it but the bike doesen't start again, i suppose that the guilty is the starter relay! 'cause doesen't switch on\off
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vroom1776 Serious Thumper Offline Posts: 2110 Gender:	Re: Melted Electrical System Reply #7 - 06/21/06 at 09:10:25 one fuse popped, but the rectifier is definitely dead. I've got one coming from ebay.
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slavy

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Re: Melted Electrical System
Reply #8 - 06/21/06 at 09:12:24

A pinched tai light wire WILL NOT melt the entire wiring unless You have been messing with it and it is "modified".
Unplug the connector of the Ign Switch and check do You have power in the RED wire of the w. harness. If there is power , plug back the ign. switch and turn it ON- check for power in the O and O/B wires. If Yes, the dash bord should light up and the horn should work.
If there is no power in the R wire that feeds the ign. switch- FUSE. This is most probable cause of Your problem.

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The arificial intelligence is no match for the natural stupidity

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vroom1776 Serious Thumper Offline Posts: 2110 Gender:	Re: Melted Electrical System Reply #9 - 06/21/06 at 10:44:07 Slavy, yeah, tried that. no good. Both hot leads of the of the bulb were shorted to the ground, not just one. Popped one 20A fuse. popped the rectifier. Electrical mods: no horn, no turn signals, 6 amp spdt hi/low/off switch from radio shack. no turn sig relay, no clutch interlock.
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vroom1776

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Re: Melted Electrical System
Reply #10 - 06/22/06 at 10:53:17

Dummy says:

vroom1776 wrote on 12/31/69 at 16:00:06:

Slavy,

yeah, tried that. no good. Both hot leads of the of the bulb were shorted to the ground, not just one. Popped one 20A fuse. popped the rectifier.

Electrical mods: no horn, no turn signals, 6 amp spdt hi/low/off switch from radio shack. no turn sig relay, no clutch interlock.

Okay, Like I said: S4B: I'm an idiot. Did not read the psot closely enough. Also, $4 Multimeters are unsurprisingly garbage. Rect seems to work.

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