SuzukiSavage.com - Need help, wiring issues

B1-66er

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Need help, wiring issues
05/01/11 at 06:49:26

Was putting the bike back together yesterday and I reconnected the battery and turned the key to check things. Then smoke came pouring out from under the tank. I pulled the tank off and there is a group of four wires(two orange, one orange/blue, and one green) that are all melted together. I'm pretty sure they just go to a relay. I can't find anything in the wiring diagram that makes sense. Anyone have any idea what they are and what might have caused the problem? Bike is an 88.

Thanks

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Serious Thumper

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Re: Need help, wiring issues
Reply #1 - 05/01/11 at 06:58:04

Putting the bike back together,.....meaning what ?

One thing is for certain, you have a "short circuit" to ground,....meaning that somewhere the positive and negative got together,......meaning that a hot wire got connected to either a ground wire, or the frame.
I think I would start start looking at what you "put back together"

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Rich
'07 S40 Blvd stocker, except drilled OEM exhaust and white spacer mod...1/2 (.055)

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B1-66er Full Member Offline I've been everything you want to be. Posts: 124 Eastern Ohio Gender:	Re: Need help, wiring issues Reply #2 - 05/01/11 at 07:50:11 I put the tank back on. I did mess with the wiring for there turn signal and headlight switches, but I had turned the key on at least twenty times since doing that. I think maybe one of the wires just got pinched and grounded out. Do you have any idea if that's a relay?
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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28886 L.A. California Gender:	Re: Need help, wiring issues Reply #3 - 05/01/11 at 08:38:21 Well if clymers color coding is correct, then the orange/blue and the green would be the side stand relay. The orange is hot and runs everywhere.
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B1-66er Full Member Offline I've been everything you want to be. Posts: 124 Eastern Ohio Gender:	Re: Need help, wiring issues Reply #4 - 05/01/11 at 09:17:52 I was thinking that too, but the clymers only has three wires going to the relay, that's what confused me. How would I go about bypassing that if I just want to eliminate it?
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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28886 L.A. California Gender:	Re: Need help, wiring issues Reply #5 - 05/01/11 at 09:44:57 where is the relay? and how big are the wires?
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justin_o_guy2

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Re: Need help, wiring issues
Reply #6 - 05/01/11 at 10:13:56

Find damaged wires, remove, replace, check with VOM before reconnecting battery. IF theres still a problem after running the wires where they Have to Go in order to run the bike,, then you can fix it, fair chance ya peenched a warr & started a high speed electron transferal system, which created intense heat,,,, Dont be doin that!

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B1-66er Full Member Offline I've been everything you want to be. Posts: 124 Eastern Ohio Gender:	Re: Need help, wiring issues Reply #7 - 05/01/11 at 10:23:30 Relay is under left side of tank. It's in a rubber boot thing that slides onto a the frame to hold it in place.
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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28886 L.A. California Gender:	Re: Need help, wiring issues Reply #8 - 05/01/11 at 10:45:11 yeah, think that's the sidestand relay.
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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28886 L.A. California Gender:	Re: Need help, wiring issues Reply #9 - 05/01/11 at 10:50:53 SSM shows 4 wires for a '96 green, orange, orange/blue, orange
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Serowbot YaBB Moderator ModSquad Offline OK.... so what's the speed of dark? Posts: 28660 Tucson Az Gender:	Re: Need help, wiring issues Reply #10 - 05/01/11 at 11:00:59 I had an under-seat fire (no, not that... ...), and the source was where the wiring was the most burnt... Follow the trail of destruction... ...
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B1-66er Full Member Offline I've been everything you want to be. Posts: 124 Eastern Ohio Gender:	Re: Need help, wiring issues Reply #11 - 05/01/11 at 11:20:23 Does anyone know what I'd have to do to eliminate the relay and switch? Also, would those wires burning keep the lights from getting power, or do you think I blew the fuse as well?
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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Need help, wiring issues Reply #12 - 05/01/11 at 11:27:55 B1-66er wrote on 05/01/11 at 11:20:23: Does anyone know what I'd have to do to eliminate the relay and switch? Also, would those wires burning keep the lights from getting power, or do you think I blew the fuse as well? You gotta look t the fuses to now,,
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verslagen1

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Re: Need help, wiring issues
Reply #13 - 05/01/11 at 11:34:09

The sidestand switch is not extremely important, but if you threw it in to a left hand turn with it down it'll either go up very quickly or toss you on yer biscuits. just saying is all.

if it's just the relay you're cutting out or the circuitry?

short the orange to orange/blue. cut the green.

circuitry will take more looking at.

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B1-66er Full Member Offline I've been everything you want to be. Posts: 124 Eastern Ohio Gender:	Re: Need help, wiring issues Reply #14 - 05/01/11 at 11:53:53 I just wanted any easy fix without doing more wiring. But if I gotta jump wires, I'll just run new ones and keep the switch.
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