SuzukiSavage.com - Bike stalling when put into gear.

FreeSpirit Serious Thumper Offline Joy is my Compass ! Posts: 3823 North Georgia Gender:	Re: Bike stalling when put into gear. Reply #15 - 09/29/09 at 08:46:18 babyhog wrote on 09/29/09 at 08:04:10: Stick around here Angie, you'll learn things you never even wanted to know.... LOL BTW, mine doesn't have a kickstand light... as far as I know... Thanks for putting that into words.I feel better already
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bill67 Serious Thumper Offline old tired Posts: 8517 genoa city wisconsin Gender:	Re: Bike stalling when put into gear. Reply #16 - 09/29/09 at 08:50:39 There is no kickstand light
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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28884 L.A. California Gender:	Re: Bike stalling when put into gear. Reply #17 - 09/29/09 at 08:59:29 Yes there is if it's an '86
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T Mack 1 - FSO

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sold 2001 LS650 for
a 1986 XLH1100

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Re: Bike stalling when put into gear.
Reply #18 - 09/29/09 at 10:31:51

Owning a bike that does not have the interlocks, I can say, there are safety interlocks that are good and some that make you scratch you head as to "what-were-they-thinking" .

Important one is the "If in gear, don't let it start unless clutch lever is pulled in" . I want to figure out a way to install that on the XLH1100. You haven't lived until you get jerked across the garage because you oops'd and started the bike in gear without pulling in the clutch lever. Even worse is when you "reach across" and start while standing next to the bike. Trust me.... Embarrassed

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The side-stand switch is a head scratcher. If you pull out with it down, first left turn you make it should touch and come up. Anyone that bumped the bike forward accidentally or parked on a hill the wrong way, knows that the side stand can fold up fairly easily. While riding, it may be a bit of a thud and that might wake you up a bit.... so I guess the scare could cause you to crash.

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Now, as for starting when the bike is in neutral, many bikes I had allowed you to start when in neutral without the clutch lever pulled in and still had the requirement to pull in the clutch lever when in gear. So,.... I modified the Savage to do the same and liked it a lot. It's easily to do on the LS650/S40 and since the neutral switch is a non-adjustable switch you don't have to worry about it going out of adjustment. HOW: A fog light relay from the local auto parts store. Placed under the tank, you can get switched power to run the actuator coil from the orange wire and then you can tap into the blue neutral light wire for the switched ground to complete the circiut. Then the two "switch" leads of the relay go to the two Yellow/w green stripe wires in the fat connector under the tank, which are the clutch lever switch wires. What happens is, when neutral light is on, the relay engages, shorting out the clutch lever switch, effectively bypassing it. But if in gear, the N light is not on so no relay power, so the lever needs to be pulled. NOTE: the occasional pinched neutral light wire, where the light is always on, ALWAYS needs to be addressed even without this mod.

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30% of being mechanical is confidence/30% is knowing to go slow when needed/30% is looking repeatedly at what you have/10% is dumb luck Wink

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justin_o_guy2

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What happened?

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East Texas, 1/2 dallas/la.

Re: Bike stalling when put into gear.
Reply #19 - 09/29/09 at 12:44:14

Important one is the "If in gear, don't let it start unless clutch lever is pulled in" . I want to figure out a way to install that on the XLH1100. You haven't lived until you get jerked across the garage because you oops'd and started the bike in gear without pulling in the clutch lever.

If you are serious about it, If youd post the wiring diagram, start & ignition circuits, I bet we could figure out a way to go about it.
A pic of the clutch lever & the clutch actuator as it passes thru the case & surrounding area, too.

The Savage has a microswitch mounted up under the clutch lever with a tab hanging down to actuate it. Hopefully theres room up under the lever to mount a switch & attach a small tab to actuate the switch.Its a normally closed switch, held "Open" unless the clutch is pulled. When you go shopping for a switch, ask for a normally closed switch.

If theres no room there then may be down on the actuator arm & if not there, then a switch on the cable housing & an actuator that travels on the cable itself would work, but it might be a little trickier to do. But its doable.

As stated above,unless you go with a relay youll have to pull the clutch even in neutral.

SO, If I hit the starter switch & its in gear & I havent pulled the clutch, just exactly what is it that doesnt get the 12 volts?

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The people never give up their liberties but under some delusion.- Edmund Burke.

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T Mack 1 - FSO

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sold 2001 LS650 for
a 1986 XLH1100

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Re: Bike stalling when put into gear.
Reply #20 - 09/30/09 at 19:28:29

justin_o_guy2 wrote on 09/29/09 at 12:44:14:

Important one ..........

If you are serious about it, If youd post the wiring diagram, start & ignition circuits, I bet we could figure out a way to go about it.
A pic of the clutch lever & the clutch actuator as it passes thru the case & surrounding area, too.

The wire diag in the HD serv manual is not what I would call a professional creation. Usable yes, but it could have been drawn more to the standard electrical / electronic methods. It's not the wiring I'm too concerned about, I am an electronic tech. It's figureing out where to put a switch. I do have some tiny lever type micro switches that are both NO & NC. Other prioriies first though.

justin_o_guy2 wrote on 09/29/09 at 12:44:14:

The Savage ..........

SO, If I hit the starter switch & its in gear & I havent pulled the clutch, just exactly what is it that doesnt get the 12 volts?

There is no power going to the starter switch, so it's like hitting nothing. It's a little hard to trace on the wiring diagrams. I did notice that the factory service manual wiring diagrams are easier to read than Clymers. Well, for people have past experience reading wiring diagrams....

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Engineers design things, Technicians make them work.
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30% of being mechanical is confidence/30% is knowing to go slow when needed/30% is looking repeatedly at what you have/10% is dumb luck Wink

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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Bike stalling when put into gear. Reply #21 - 09/30/09 at 20:45:32 Well, Unca Sam force fed me electronics for 9 months, so I am trained well enough to screw things up in less time than most folks, but I can help with this kind of thing well enough. Sounds like you know what to do as well as anyone tho. Holler if I can help.
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Angie Senior Member Offline Anybody can be normal, where's the fun in that? Posts: 334 Iowa Gender:	Re: Bike stalling when put into gear. Reply #22 - 10/01/09 at 07:40:25 I guess I always start in neutral anyway. In fact, I just make sure its in neutral and fire it up before I get on. Then I can get my helmet on, backpack, etc and by the time I mount up she's warmed up and ready to ride.
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Angie

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Anybody can be
normal, where's the
fun in that?

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Iowa
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Re: Bike stalling when put into gear.
Reply #23 - 10/01/09 at 07:47:44

mack - had to laugh at your comment about reaching across your bike to start it and forgetting that it was in gear. I was in the habit of leaving the Sportster in gear when I shut if off cause I was paranoid about it rolling. When hubby would get on it to ride, he'd get rather testy that I had left it in gear. Cool

So enough crabbing from him finally got me trained to shut it off in neutral. Personally, even though Im the only one that rides the Savage, and I always shut it off in neutral, I still check to make sure the green neutral light is on before I fire it up. I can only imagine how much I'd hear about it if I started my bike in gear and it tipped or ran into the Harley. Undecided

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