Donate!
Welcome, Guest. Please Login or Register :: View Members
Pages: 1
Send Topic Print
Electrical issues (Read 59 times)
Darryl
YaBB Newbies
*
Offline

SuzukiSavage.com
Rocks!

Posts: 34

Electrical issues
05/05/26 at 20:11:31
 
I'm putting my newly acquired '88 back together. When I fixed the long dormant foot brake light switch I tested all the lights to make sure they worked. Today I replaced the damaged clutch and front brake levers with some questionable quality new ones, and again attempted to check the lights. Now nothing works. The battery is up and there is power to three of the four wires to the relay above the right shock, and to a single red wire heading up under the tank.  No power to the key switch or anywhere else.  So are there fuses somewhere? The only wires I unplugged were those from the magneto. Plus the ones on the new clutch and brake levers. I didn't have the tank off - is there anything under it I should check? At this point I'm stumped. While eating dinner I had a thought - the first time I tested the lights I had the bike on a stand. This time it was on the sidestand. So I ran out to the shop, stood it up, and folded the sidestand. Still nothing. Rats.
Back to top
 
 
  IP Logged
Dave
YaBB Moderator
ModSquad
*****
Online

SuzukiSavage.com
Rocks!

Posts: 18750
Camp Springs, Kentucky
Gender: male
Re: Electrical issues
Reply #1 - 05/06/26 at 03:41:18
 
The fuses are located in a little plastic holder that is located on the right side of the bike, that just barely protrudes from under the seat.
Back to top
 
 

Someday I will be old......But not today!

  IP Logged
Darryl
YaBB Newbies
*
Offline

SuzukiSavage.com
Rocks!

Posts: 34

Re: Electrical issues
Reply #2 - 05/06/26 at 13:48:14
 
Ah yes, the one I thought was a relay, since it says "relay" on it.  One fuse was blown and its replacement blew immediately. So any suggestion where to look next? I'm going to unplug both the clutch and front brake switches since they are the only wiring I had fooled with. But have to go get more fuses first.  I read somewhere that the decomp system can cause electrical problems. I have no idea how to test that.
Back to top
 
 
  IP Logged
Ruttly
Serious Thumper
*****
Offline

Thumpers Rule

Posts: 5561
Manteca , CA
Gender: male
Re: Electrical issues
Reply #3 - 05/08/26 at 00:26:23
 
Two fuses , one for decompressor solenoid , other fuse is for everything else. Both together in a small white plastic case. If fuse blows quick you have a short. Look where you last worked on it. Battery cables loose can cause the fuse to blow . Have fun , good hunting !
Back to top
 
 

The Topic Terminator
  IP Logged
Darryl
YaBB Newbies
*
Offline

SuzukiSavage.com
Rocks!

Posts: 34

Re: Electrical issues
Reply #4 - 05/08/26 at 12:27:27
 
I unplugged the two switches I had been messing with and replaced the fuse, turned the key and it blew again. So next I will re-check the battery connections and every other wire I touched. I downloaded the wiring diagram so that should help. Any other suggestions would be appreciated.
Back to top
 
 
  IP Logged
Darryl
YaBB Newbies
*
Offline

SuzukiSavage.com
Rocks!

Posts: 34

Re: Electrical issues
Reply #5 - 05/10/26 at 20:10:14
 
I unplugged every wire connector under the seat and LH cover with the idea that I would plug them back in until the fuse blew, but it again blew immediately upon turning the key. I also checked the battery connections.  Tomorrow I will remove the handlebar switches to make sure I didn't screw them up. Other than that I'm running out of ideas. I hate to have to take it to the dealer but that may be coming.
Back to top
 
 
  IP Logged
Darryl
YaBB Newbies
*
Offline

SuzukiSavage.com
Rocks!

Posts: 34

Re: Electrical issues
Reply #6 - Yesterday at 13:03:08
 
As I just posted under The Cafe, I removed the seat and tank, and unplugged every connection I could find.  With a fresh fuse in place, I started plugging them back in until it popped again.  It was the plug under the tank for the RH handlebar switches.  I thought I had narrowed it down until I noticed 7 wires at the plug but only 6 at the switches, and wires having current flow that shouldn't.  After slicing open the sheathing I found that 3 wires are joined together inside the sheathing, which therefore sends current from the orange wire back upline to the plug and who knows where beyond that.  This is making it much more difficult to solve since the wiring diagram I downloaded here doesn't show anything like that, or match the wire colors I'm finding.  And it is all original, unmodified wiring.
Back to top
 
 
  IP Logged
DragBikeMike
Serious Thumper
*****
Offline

SuzukiSavage.com
Rocks!

Posts: 4719
Honolulu
Re: Electrical issues
Reply #7 - Yesterday at 18:33:12
 
What can you tell us about your “questionable quality” new clutch and front brake levers.  I assume the plastic plugs on each lever/switch assembly fit the existing harness.

There have been a number of changes since 1988.  I believe Suzuki added the passing lamp switch to the left hand assembly, and four-way flashers to the right hand assembly.

The late model diagram shows 10 wires on the right hand assembly plug, and eight wires on the left hand assembly plug.  The earliest model diagram shows six wires on the right hand assembly plug, and nine wires on the left hand assembly plug.  There’s all sorts of configurations in between:  1987 four RH and eight LH, 1995 seven RH and nine LH, 1996 seven RH and eight LH, 2004 eight RH and eight LH.  As you can see many different configurations.  If the plastic plugs are the same and they just add or subtract pins, it would be easy to end up in a pickle.

I would take those three wires that are joined together and un-join them.  Then see if the fuse blows.  If the fuse doesn’t blow with those three wires un-joined, start re-joining them until the fuse blows.  Then figure out where the fuse-blower goes.
Back to top
 
 

Knowledge is power.
  IP Logged
Darryl
YaBB Newbies
*
Offline

SuzukiSavage.com
Rocks!

Posts: 34

Re: Electrical issues
Reply #8 - Yesterday at 19:52:20
 
Good advice, but I think I found the problem. My plan of reconnecting plugs until the fuse blows had a flaw - if I connected the problem plug and then one upstream, the latter would appear to be the faulty circuit. So I started over in a different pattern. This time the lead to the LH grip switches was the fault, and since the horn and signal switches are not energized at rest, I figured out it was more likely in the headlight/front signal circuit. I unplugged the headlight and both signals and then plugged them back one at a time until the RH signal blew the fuse. When I got the bike the RH signal was very loose so naturally I tightened up the attaching screw.  It was still loose so I cranked on it some more. But apparently a previous owner had used screws that were too long and I ran it through the wires.  Lesson learned, and I will be checking the other side too.
As for the new clutch and brake controls, I needed a new brake reservoir so ordered a matching pair, but they are cheesy Chinese quality. The wires are a little short to fit and the brake ones were mangled anyway, so I will be extending them. Probably not the best plan but it will do for now.
Back to top
 
 
  IP Logged
Pages: 1
Send Topic Print


« Home

 
« Home
SuzukiSavage.com
05/17/26 at 03:07:18



General CategoryRubber Side Down! › Electrical issues


SuzukiSavage.com » Powered by YaBB 2.2!
YaBB © 2000-2007. All Rights Reserved.