SuzukiSavage.com - A head scratcher, clutch lever turns on starter

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A head scratcher, clutch lever turns on starter
06/13/13 at 08:06:49

So I have a 2003 that I bobbed but have the stock wiring still. I got rid of the airbox and stock seat, so I wrapped most of the wiring in electrical tape and tucked it under battery box, rectifier on the exhaust bracket. I rode through some mud the other day, so I washed it off with a wet rag, no hose. Everything was fine, I went to get gas and shake off the water. I pulled the clutch lever in and started it up, but the starter kept spinning. I let go of the clutch in neutral and it stops, engine running fine. Pull the clutch again, the starter spins and the engine chugs. Release it and everything is fine. Pull the clutch and it does it again. Release, fine. After fussing with it for a bit, I finally unplugged the clutch lever sensor on the handlebars and rode home without incident. I plugged it back in when I got home and was able to duplicate the issue. I untucked the wiring under the battery and nothing looked wet. Tucked everything back and let it sit for 15 minutes, now everything is ok again.

I didn't spray it with water or dump water on it, just slopped the rag around on the lower parts of the bike (not the handlebars or under tank connections). The starter did not get wet as far as I know. I'm not sure if the water caused a short or if I moved some connections around while i was washing it that caused the issue. Either way, it is fine now, but I am just curious which connections might be to blame in case this happens again. Has anyone has experienced this before?

Thanks,
-G

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ToesNose Serious Thumper Offline Pardon me, do you have Hot Sauce? Posts: 1993 Mooresville, NC Gender:	Re: A head scratcher, clutch lever turns on starte Reply #1 - 06/13/13 at 08:19:09 Doesn't sound like an issue from getting wet to me, most likely a short somewhere. Most likely making cross contact and got moved when you played with the wiring. I know you said it's ok now, but I would go back over everything and try to hunt it down
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hotrodbobber Junior Member Offline SuzukiSavage.com Rocks! Posts: 54	Re: A head scratcher, clutch lever turns on starte Reply #2 - 06/13/13 at 11:25:58 yea i would totaly agree souds like a problem with the wiring rather than water
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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28888 L.A. California Gender:	Re: A head scratcher, clutch lever turns on starte Reply #3 - 06/13/13 at 12:50:01 pulling the clutch in can activate the starter if you had the starter button mashed down. I'd start there.
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Digger

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Re: A head scratcher, clutch lever turns on starte
Reply #4 - 06/13/13 at 18:55:54

verslagen1 wrote on 06/13/13 at 12:50:01:

pulling the clutch in can activate the starter if you had the starter button mashed down.

I'd start there.

I agree w/ Ver.

Somehow, the bike was thinkin' that the starter button was pushed, even though it may not have been. Pulling in the clutch lever would then allow the starter motor to spin.

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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: A head scratcher, clutch lever turns on starte Reply #5 - 06/13/13 at 21:17:03 If ya dont have a volt/ohm meter & a test lite, you should. There are some clips with a pad made of several pointy little wires that can be put on insulated wires.. Not Good for the insulation, but makes gettin hooked into That wire real easy. I have 1, had it for years, no idea where to get such now,,
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12Bravo Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 628 Mid-Missouri Gender:	Re: A head scratcher, clutch lever turns on starte Reply #6 - 06/14/13 at 05:58:59 Start by checking to make sure the starter switch is NOT sticking then check wiring. The starter switch sticking is common on the Suzuki Burgman 650 and will cause the starter to spin when brakes are applied. A dirty/sticking starter switch can cause the problem you describe when pulling the clutch in.
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Digger

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Re: A head scratcher, clutch lever turns on starte
Reply #7 - 06/14/13 at 19:31:18

justin_o_guy2 wrote on 06/13/13 at 21:17:03:

If ya dont have a volt/ohm meter & a test lite, you should. There are some clips with a pad made of several pointy little wires that can be put on insulated wires.. Not Good for the insulation, but makes gettin hooked into That wire real easy. I have 1, had it for years, no idea where to get such now,,

Or, you could just drive a needle through the middle of the wire. You can then tape over the insulation damage when you are done....

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Digger
2001, Metallic Glacial Blue, Raptor Petcock, Verslavy (first hole) (otherwise, mechanically, the bike is stock), 13,xxx miles
I don't own a cage.
www.astronautbiker.com

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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: A head scratcher, clutch lever turns on starte Reply #8 - 06/14/13 at 20:27:46 Yes! You can do that,, Hold a pin or needle in pliers & put a block of wood behind the wire & POKE Away! Easy fixer
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groupus

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Re: A head scratcher, clutch lever turns on starte
Reply #9 - 06/18/13 at 16:40:52

Thanks for the replies, and sorry i've been away all weekend for a wedding. I am still recovering. Grin

I have a VOM, but i'm not sure where to start checking. Also the problem is so sporadic that it becomes difficult to duplicate. it started fine today, but was acting up by the time i got to my destination <10 min away. I did clean out the hand switches after that and I found a spider nest on the throttle side, but not in the switches. Also, the problem I'm having will cause the starter to spin and the bike to stumble, but it I try to duplicate it by holding the starter button in, it will kill it right away Undecided

not sure whats up with that.

Anyway, its functioning now again. I will report back when I find out more. Any ideas on what connections I should start testing? Huh

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Faster, faster, faster, until the thrill of speed overcomes the fear of death. ~Hunter Thompson

'03 Savage bobber. Rebuilt too many times.

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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: A head scratcher, clutch lever turns on starte Reply #10 - 06/18/13 at 20:19:23 Pull the battery negative, hook the ohm meter to the start button wires. Piddle with the buton & see if it sometimes hangs up.
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Re: A head scratcher, clutch lever turns on starte
Reply #11 - 06/19/13 at 05:39:46

justin_o_guy2 wrote on 06/18/13 at 20:19:23:

Pull the battery negative, hook the ohm meter to the start button wires. Piddle with the buton & see if it sometimes hangs up.

Clean all the switches and connectors with contact cleaner and then apply some dielectric grease. Double check the starter switch. Also don't be afraid to clean switch contacts with a scotch brite pad or fine emery cloth and don't forget the dielectric grease on all switches and connectors.

The starter switch on the Burgman 650 would occasionally stick on me and cause the same problem (starter engaging). I would check it and it would be fine then mess up at random times.

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