SuzukiSavage.com - Intermittent Short

HondaLavis

Senior Member

Offline

It's nothing
personal; the other
one came first.

Posts: 451
Plano, TX

Re: Intermittent Short
Reply #15 - 08/15/14 at 21:08:32

According to the 1996-2003 Savage wire diagram in the clymer's, your orange wire changes color after an electrical connector. It becomes a black/red wire that feeds power to your horn and dimmer switch. This orange wire originates from the orange/black coming out of the rectifier, and it feeds the neutral light and the side stand relay in addition to your identified trouble spots.

Double check everything. Does your neutral light work? If you hotwire your side stand relay, does the problem go away? That orange/black wire also feeds the rear brake light switch. Does that work?

What year is your bike? All of the same applies to the 2004, though it has even more circuits tied to that one wire.

Black and black/white are your ground wires. Wink

Back to top

"You ride a single cylinder motorcycle??"

"When you're good, one is all you need." Wink

I guess that means I'm no good anymore; I've got 4 more cylinders! '08 Yamaha FJR1300 and still '01 Savage

IP Logged

youzguyz

Serious Thumper

Offline

Posts: 2538
San Antonio, Texas
Gender: male

Re: Intermittent Short
Reply #16 - 08/16/14 at 02:34:10

pgambr, your avatar says "S40", so have to assume it is 2004 or later.

Restating what some others have said.
From looking at Clymers:
The horn and headlight hot line is black/orange. On the other side of the connector that sits under the tank on the left side, it is orange. It is not uncommon for that connector to come loose when replacing the gas tank.

If the neutral light or speedo light works, you have 12 volts to the orange wire on the chassis. You can also check that wire on the connector for the ignition switch.
If you have 12 volts on the orange line, my suggestion. Pull the tank. Reseat that connector (and maybe spray it out with contact cleaner) and see if that fixes your problem. If not, check for 12 volts on the orange side of the connector, if there, see if you get it on the black/orange side.

While this is not a multi-meter, it is my weapon of choice when looking for voltage:
http://www.harborfreight.com/circuit-tester-30779.html
It has a needle point that you can poke through the insulation or worm into the back end of connectors, and the indicator light is in the handle.

I must disagree with HondaLavis. Ground is always black/white, never black.
(Except the wire that goes from the battery to the engine for chassis ground).

Back to top

2002 - Silver (Thumper)
2000 - Green (Mad Hamish)
Most motorcycle problems are caused by the nut between the seat and the handlebars. Make sure yours isn't too tight or too loose.

IP Logged

pg Serious Thumper Offline Posts: 5273 In Transit	Re: Intermittent Short Reply #17 - 08/16/14 at 03:17:56 Thanks to all, I have been stumped! Off to work now, but I'll be sure to start checking things as soon as I get off.
Back to top	I don't make the rules, I just know what they are..... IP Logged

pg Serious Thumper Offline Posts: 5273 In Transit	Re: Intermittent Short Reply #18 - 08/16/14 at 15:22:12 I started prodding around and I after I touched this the light kicked back on. Next question, what now?
Back to top	P8160058_2.jpg I don't make the rules, I just know what they are..... IP Logged

Dave YaBB Moderator ModSquad Online SuzukiSavage.com Rocks! Posts: 18099 Camp Springs, Kentucky Gender:	Re: Intermittent Short Reply #19 - 08/16/14 at 16:59:25 If you are talking about the connector....pull it apart, spray some contact cleaner in it, and poke it back together, and wiggle it around a bit to help restore the connections. Dave
Back to top	Someday I will be old......But not today! IP Logged

pg Serious Thumper Offline Posts: 5273 In Transit	Re: Intermittent Short Reply #20 - 08/16/14 at 17:05:13 I put the left headlight / horn switch assembly back together and I'm back to square one. NO headlight.
Back to top	I don't make the rules, I just know what they are..... IP Logged

pg

Serious Thumper

Offline

Posts: 5273
In Transit

Re: Intermittent Short
Reply #21 - 08/17/14 at 14:42:47

pg wrote on 08/16/14 at 17:05:13:

I put the left headlight / horn switch assembly back together and I'm back to square one. NO headlight. Angry

I learned a bit more about my problem; although, I still have a long way to go.

1. Regarding the connector (Picture previously provided), if you gently brush up to it the current travels correctly.

2. When that is working correctly the Headlight / Dimmer / Horn assembly has power.

3. When the Headlight / Dimmer / Horn assembly has power the head light will not come on unless you click the passer switch.

4. Regarding the connector, all those wires travel to the cutoff assembly that is near the throttle?

5. Now I'm really confused, please help if possible.

Thanks.

Back to top

I don't make the rules, I just know what they are.....

IP Logged

verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28886 L.A. California Gender:	Re: Intermittent Short Reply #22 - 08/17/14 at 14:57:03 At least you've narrowed it down to a connector or the control attached to it. What year did you say your bike was? I would start looking for a cheap replacement control. Swapping it out might fix it.
Back to top	Versey's Place Tech Section Index IP Logged

pg Serious Thumper Offline Posts: 5273 In Transit	Re: Intermittent Short Reply #23 - 08/17/14 at 15:03:50 It's an 06. Also, the last time it did this the battery was at the end of it's life, that was 1.5 years ago. Just an observation and or similar circumstance. I'll have to start looking as well, thanks Verslagen.
Back to top	I don't make the rules, I just know what they are..... IP Logged

verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28886 L.A. California Gender:	Re: Intermittent Short Reply #24 - 08/17/14 at 16:04:41 here's one for an 07 http://www.ebay.com/itm/07-Suzuki-S40-Boulevard-LS650-650-RIGHT-HANDLEBAR-CON...
Back to top	Versey's Place Tech Section Index IP Logged

pg Serious Thumper Offline Posts: 5273 In Transit	Re: Intermittent Short Reply #25 - 08/17/14 at 16:16:43 Thanks Verslagen! I will get that on the way and book mark Pinwall Cycles webpage.
Back to top	I don't make the rules, I just know what they are..... IP Logged

pg Serious Thumper Offline Posts: 5273 In Transit	Re: Intermittent Short Reply #26 - 08/21/14 at 14:30:00 I got the part from Pinwall; incidentally, they shipped very fast and seem like a real good source for used parts. Regardless, same crap different day. I suppose my next option is to start clipping and rewiring. Please let me know your thoughts.
Back to top	I don't make the rules, I just know what they are..... IP Logged

HondaLavis Senior Member Offline It's nothing personal; the other one came first. Posts: 451 Plano, TX	Re: Intermittent Short Reply #27 - 08/21/14 at 23:26:47 Did you check the large connector under the gas tank for any corrosion? If certain wires are losing connectivity when you move them, then narrow down the individual wires and places with a multimeter. Don't assume that splicing in a dozen wires in place of that connector is a good idea.
Back to top	"You ride a single cylinder motorcycle??" "When you're good, one is all you need." I guess that means I'm no good anymore; I've got 4 more cylinders! '08 Yamaha FJR1300 and still '01 Savage IP Logged

pg

Serious Thumper

Offline

Posts: 5273
In Transit

Re: Intermittent Short
Reply #28 - 08/22/14 at 14:49:13

Quote:

Did you check the large connector under the gas tank for any corrosion?

Thanks for the reply Hondalavis. Yeah, the connector that sits on the right of the tank had just a little bit of corrosion. I tried replacing the front half with what Versalgen recommended. That was a real good idea, just no luck. I'm looking for my best next option.

Back to top

I don't make the rules, I just know what they are.....

IP Logged