SuzukiSavage.com - Electrical problem. She won't even try to crank

DavidOfMA

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Getting back in gear
after a long time
away

Posts: 336
Beverly, MA
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Re: Electrical problem. She won't even try to cran
Reply #15 - 03/20/13 at 22:15:48

JRLeathercraft wrote on 03/20/13 at 14:03:13:

This might sound crazy - but how old is the battery?

Try giving it a charge.

Jay

OP says he bought and installed a new battery:
Quote:

9) Bought and installed a brand new battery. (The old one dropped from 12V to 10v when I turned the ignition key to the "on" position) The new one drops from 12.8v to 12.2v (much better).

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- David

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drivingmenuts

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1997 Suzuki LS650
Savage

Posts: 7
San Francisco, CA
Gender: male

Re: Electrical problem. She won't even try to cran
Reply #16 - 03/22/13 at 00:56:48

Yes!!!! I finally got the bike to turn over! Turns out my problem was the "side stand relay" which is on the left side of the bike, near the horn and ignition coil. I had originally disregarded it because I'd assumed it was a turn signal relay. But thanks to people's advice, and Bobberts thorough run down of the electrical system, I realized it was actually a safety relay that supplies power directly to the kill switch. AND I fixed it by accident... I took it off to check for continuity, and at first I had a bad reading. THEN i dropped it. Checked it again, and the reading was good! I guess that drop knocked some things into place.

Lessons learned:
1) Don't assume you know what a component is. ALWAYS refer to a good wiring diagram.
2) Give your relays a tap or two before tearing into the harness and pulling your hair out.

Next steps:

Put the ignition cap back on and test for a spark. If I get a good spark, I will take out my jumper wires used to bypass the safety switches, one by one, and keep checking to make sure it all works. Then start her up, tune her up, and hand her back over to what will be a very happy girl. Grin

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ToesNose Serious Thumper Offline Pardon me, do you have Hot Sauce? Posts: 1993 Mooresville, NC Gender:	Re: Electrical problem. She won't even try to cran Reply #17 - 03/23/13 at 04:08:46 Glad to hear you resolved the problem before pulling all your hair out
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drivingmenuts YaBB Newbies Offline 1997 Suzuki LS650 Savage Posts: 7 San Francisco, CA Gender:	Re: Electrical problem. She won't even try to cran Reply #18 - 03/25/13 at 19:10:27 Ok, got the starter to turn over, and checked for a spark... no spark. Progress... but more tests needed! Ah.
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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Electrical problem. She won't even try to cran Reply #19 - 03/26/13 at 07:25:54 When you get this thing going, you Should get the Full ON "Knight in Shining Armor who saved the damsel in distress" thank you.
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drivingmenuts

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1997 Suzuki LS650
Savage

Posts: 7
San Francisco, CA
Gender: male

Re: Electrical problem. She won't even try to cran
Reply #20 - 04/05/13 at 18:39:47

Ok, I'm stuck. I'm not getting a spark. Tested the ignition coil and it's within specs and is receiving 12V. The pickups tested within spec. I'm afraid the problem is the terribly expensive TCI box. Before I go buying one, I want to be sure. Is there anyone in the San Francisco area that would be willing to let me swap their good TCI box with my potentially bad one? Will only take 30 seconds. I'll buy you a beer? Give you a few bucks? Any takers? Undecided

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drivingmenuts YaBB Newbies Offline 1997 Suzuki LS650 Savage Posts: 7 San Francisco, CA Gender:	Re: Electrical problem. She won't even try to cran Reply #21 - 04/05/13 at 18:41:44 Oh, and of course by "swap" I don't mean swap forever. I mean I want to put your good TCI box on my bike and see if my bike gets a spark. Then I will give you back your box.
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drivingmenuts

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1997 Suzuki LS650
Savage

Posts: 7
San Francisco, CA
Gender: male

Re: Electrical problem. She won't even try to cran
Reply #22 - 04/20/13 at 20:50:56

Ok. I went through all the electric, AGAIN, and I had a feeling my no spark issue was a faulty TCI box. Luckily I found one on Ebay for $40!! Put it in and and I got a spark. I hate being right all the time... Grin

NEW PROBLEM: I got her running, all tuned up and ready to ride. I checked the charging system and it's fine (charges at 14V) And then I noticed the gas leak.

When the bike is running, gas POURS out of the air box breather hose. (The one dangling under the battery box, with the removable cap)

Opened up the air box and it's totally dry. No gas in the air box. I'm hoping this is some kind of hose routing issue, as I'd rather not pull the carb.

Anyone familiar with this?

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savagerider87 Full Member Offline Riding a quality Japanese machine since '13 Posts: 224 Northern NY Gender:	Re: Electrical problem. She won't even try to cran Reply #23 - 04/21/13 at 05:42:55 Im gonna say its the clutch switch.... had the same problem with mine, try jumping it with a piece of wire and it might just fire up. Good luck
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savagerider87

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Riding a quality
Japanese machine
since '13

Posts: 224
Northern NY
Gender: male

Re: Electrical problem. She won't even try to cran
Reply #24 - 04/21/13 at 05:47:03

drivingmenuts wrote on 04/20/13 at 20:50:56:

Ok. I went through all the electric, AGAIN, and I had a feeling my no spark issue was a faulty TCI box. Luckily I found one on Ebay for $40!! Put it in and and I got a spark. I hate being right all the time... Grin

NEW PROBLEM: I got her running, all tuned up and ready to ride. I checked the charging system and it's fine (charges at 14V) And then I noticed the gas leak.

When the bike is running, gas POURS out of the air box breather hose. (The one dangling under the battery box, with the removable cap)

Opened up the air box and it's totally dry. No gas in the air box. I'm hoping this is some kind of hose routing issue, as I'd rather not pull the carb.

Anyone familiar with this?

ok ignore my last reply, sounds like a stuck needle valve in the carb try tapping on the side of the carb lightly, but if that doesn't help youll have to give it a good cleaning

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1987 650 F Jardine exhaust,custom leather lever covers,and Corbin seat
2014 Star Bolt R-Spec

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