SuzukiSavage.com - Testing Safety Switches

86-Savage

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Testing Safety Switches
05/24/15 at 07:12:27

Hey everyone,

I am hoping someone can help me out.

I own an 86 Savage and it won't start. I press the starter button and nothing happens. The lights come on and the battery is always on a tender.The other day I had to press the starter button several times to get the starter to fire, went for a ride and parked the bike. I have checked the main fuses, fiddled with the kickstand, opened the kill switch to clean and check contacts. Nada.

How do I check the switches to see if they are faulty?
Any other suggestions much appreciated as well.

Thanks,
Jose

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Kris01 Serious Thumper Offline Eat, sleep, RIDE! Posts: 3767 Tennessee Gender:	Re: Testing Safety Switches Reply #1 - 05/24/15 at 07:47:23 Try removing the wires from the switches and shorting them together. If it cranks normally, you've found your culprit.
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86-Savage YaBB Newbies Offline Posts: 30 Ontario, Canada Gender:	Re: Testing Safety Switches Reply #2 - 05/24/15 at 12:49:37 I am wondering if "shorting" the wires together means connecting them to each other? I read in the help section to use a paper clip but not sure what to connect. Don't want to make a costly mistake. Thanks.
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justin_o_guy2

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East Texas, 1/2 dallas/la.

Re: Testing Safety Switches
Reply #3 - 05/24/15 at 14:00:08

Since the clutch switch is so easy to get to, I would start with that.
First, be sure that you are in.neutral . If that switch is not right and the stand is down I don't know if it's gonna turn over.

And yeah, paperclip,opened up,piece cut off, and connect the two wires that plug into the clutch switch.

Could just be the start switch itself. Mine went funky, took it apart, cleaned up, all good.

BUT, there is some small stuff in there and a spring.

I always sweep the floor, and cover the tank with a towel in case I fumble a tool.
I sweep so if something gets away the floor is clean and there isn't a bunch of crud for it to hide behind.

Everyone who has a bike needs a volt meter, available for less than ten bucks at Harbor Freight.
You can test a switch real easy.

Never check Ohms on anything with voltage to it.

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

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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: Testing Safety Switches Reply #4 - 05/24/15 at 14:36:35 The 2 wires on the clutch lever can be touched together (shorted), don't touch them to the handle bar or other frame member. The kickstand safety is more involved, so another time. kickstand down, must be in neutral. kickstand up, can be in gear. both cases, must pull in clutch to start.
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86-Savage YaBB Newbies Offline Posts: 30 Ontario, Canada Gender:	Re: Testing Safety Switches Reply #5 - 05/24/15 at 16:01:15 Awesome, thanks for the replies, going to check them now and will report the outcome.
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86-Savage YaBB Newbies Offline Posts: 30 Ontario, Canada Gender:	Re: Testing Safety Switches Reply #6 - 05/24/15 at 16:50:38 No luck...im going to let the pros have a look before I touch something and end up spending more than the current issue. Thanks very much for the assistance.
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justin_o_guy2

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East Texas, 1/2 dallas/la.

Re: Testing Safety Switches
Reply #7 - 05/24/15 at 17:03:03

That's just one of several things. You might wanna slow down,take a breath and work through this. We have seen those professionals destroy a couple of engines just doing an oil change.
Might take some time, but this bunch can probably walk you through this.
You're Gonna be needing tools if you intend to own a bike...
Tools cost less than labor.

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

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Kris01 Serious Thumper Offline Eat, sleep, RIDE! Posts: 3767 Tennessee Gender:	Re: Testing Safety Switches Reply #8 - 05/24/15 at 19:55:46 86-Savage wrote on 05/24/15 at 16:50:38: im going to let the pros have a look... NOOOOO! DO NOT DO THIS! These guys are the pros! They are more likely to fix your problem "long distance" than any mechanic who actually has his hands on your bike!
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86-Savage YaBB Newbies Offline Posts: 30 Ontario, Canada Gender:	Re: Testing Safety Switches Reply #9 - 05/25/15 at 05:27:45 Ok, back to the drawing board I guess. I have a volt meter...battery tested 12.47 v so battery is good.
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justin_o_guy2

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Re: Testing Safety Switches
Reply #10 - 05/26/15 at 04:09:28

Glad you are back in the fight.
Okay, what do you know, just common sense?

You know that the start switch hasta have 12 volts in, and, when pushed, out.. now, prove power to that switch..

An easy to use and handy tool is a test light. Clip to ground, poke and find voltage. Can be done thru insulation, but can also easily get poked into your finger,so,be careful. You may need a wire with clips on each end to be an extension for a troubleshooting tool.

This may not be easy, but YOU will know how to figure out problems and you'll develop a tool collection and save a ton of cash. And one day you'll be talking someone through troubles.

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

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86-Savage YaBB Newbies Offline Posts: 30 Ontario, Canada Gender:	Re: Testing Safety Switches Reply #11 - 05/27/15 at 09:26:07 When it comes to electrical diagnosing I am lost. I picked up a test light and alligator clips. I am going to try and figure out the electrical path from battery to the various switches and if they are good I will need to see if the starter motor is pooched.
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86-Savage YaBB Newbies Offline Posts: 30 Ontario, Canada Gender:	Re: Testing Safety Switches Reply #12 - 05/27/15 at 09:41:20 When it comes to electrical diagnosing I am lost. I picked up a test light and alligator clips. I am going to try and figure out the electrical path from battery to the various switches and if they are good I will need to see if the starter motor is pooched.
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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Testing Safety Switches Reply #13 - 05/27/15 at 10:15:07 starter motor test is simple, BE SURE YOU ARE IN NEUTRAL, connect cables to the car battery,
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86-Savage

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Re: Testing Safety Switches
Reply #14 - 05/27/15 at 10:46:26

What I found with volt meter:

Stop switch in ON - no continuity (fail)
Stop switch in OFF - no continuity

Start switch pressed - low continuity (pass)
Start switch released - no continuity (pass)

Rear brake lever engaged - no continuity (fail)
Switch opened and one wire snapped off from solder

According to repair manual the entire harness needs to be replaced.

I am going to test the clutch and kickstand switches as well since bike is apart and the old gal may be getting brittle wires.

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