Bike dies/won't start. Electrical problem. - Page 2

Meme · 01-04-2012, 05:09 PM

If I take the seat off, the storage box out, and rap on any of the 3 parts that are mounted to the front of the rear fender, it will immediately kick over (with the clutch tied down with a bandanna and the starer button pressed). I think the parts are so close that any vibration reaches all 3 of them. I only kick the frame when it happens and I am riding it (it's quicker).

Here are the parts under the storage box. The first pic is the fuse box and flasher as seen from the top, with part of the igniter visible in the lower right. The second pic is the igniter, taken from the right side of the bike with the side cover off, and not level, as the angle of the chain shows.

Gz Rider · 01-04-2012, 08:10 PM

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Meme · 01-05-2012, 05:52 PM

The dirt on the fuse box is just dust. I'm in Reno, Nevada and the desert is dusty.

I took things apart yesterday, pulling the fuse box off of the fender and separating the wires so I could get to each one individually. Believe it or not the problem is associated with the flasher relay. The wire running from the ignition fuse to the flasher relay, under the fuse box, seems to be the one causing problems. I'm not sure if the wire is broken at the crimp up in the fuse box or the relay itself is bad, but I'm going to try the relay first. I did try cleaning all the contacts on the relay by scraping them with a knife. I didn't have any contact cleaner with me, so just made due with what I had. I can't tell if it made any difference. It is a pain not having it at home to work on. The bike seems to have the problem much less now, but I didn't ride it very far, and still don't want to try to ride it home yet.

Meme · 01-05-2012, 06:12 PM

Well, the local Suzuki shop doesn't have the relay in stock, and it's $85, for a part I might not need. This is frustrating to say the least.

Gz Rider · 01-05-2012, 07:45 PM

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Meme · 01-06-2012, 07:13 AM

Quote:

Originally Posted by Gz Rider

Do your turn signals flash?

Yep. When it works everything works, and when it won't run the turn signals still work. Go figure.

Gz Rider · 01-06-2012, 10:44 AM

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mrlmd1 · 01-06-2012, 11:11 AM

If the turn signals work, then how can the flasher be the problem? That makes no sense. If you had a short somewhere, you would be blowing a fuse.
Sounds to me like you have a loose battery connection intermittently losing all power to the bike. Did you check and/or clean the connections at the battery terminals?

Gz Rider · 01-06-2012, 11:52 AM

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mrlmd1 · 01-06-2012, 02:41 PM

I disagree - a short big enough to stop the bike dead would certainly blow a fuse. That's why, being an intermittent problem, it is much more likely to be a loose connection somewhere in the line from battery to the plug. Start at the battery and go through the whole system 'till you find it and you will need the wiring diagram on here to help trace the ignition system. It could even be a dirty or loose connection from the wire at the plug on the other end of the line. Is the plug wire pushed/screwed all the way in to the connector cap on the end, the one that clips on to the plug?
If the turn signals still work when the bike won't turn over, that sort of eliminates a bad battery connection (but you should check it anyway), and limits your looking to the entire path through the ignition system, including all the kill switches, for a loose connection somewhere.

01-04-2012, 05:09 PM	#11
Meme Member Join Date: Oct 2009 Location: Reno NV Posts: 57	Re: Bike dies/won't start. Electrical problem. If I take the seat off, the storage box out, and rap on any of the 3 parts that are mounted to the front of the rear fender, it will immediately kick over (with the clutch tied down with a bandanna and the starer button pressed). I think the parts are so close that any vibration reaches all 3 of them. I only kick the frame when it happens and I am riding it (it's quicker). Here are the parts under the storage box. The first pic is the fuse box and flasher as seen from the top, with part of the igniter visible in the lower right. The second pic is the igniter, taken from the right side of the bike with the side cover off, and not level, as the angle of the chain shows. Login or Register to Remove Ads
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01-04-2012, 08:10 PM	#12
Gz Rider Senior Member Join Date: Aug 2011 Posts: 852	Re: Bike dies/won't start. Electrical problem. ... __________________ *Alert - This person is a douche. Use these comments and advice at your own risk*
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01-05-2012, 05:52 PM	#13
Meme Member Join Date: Oct 2009 Location: Reno NV Posts: 57	Re: Bike dies/won't start. Electrical problem. The dirt on the fuse box is just dust. I'm in Reno, Nevada and the desert is dusty. I took things apart yesterday, pulling the fuse box off of the fender and separating the wires so I could get to each one individually. Believe it or not the problem is associated with the flasher relay. The wire running from the ignition fuse to the flasher relay, under the fuse box, seems to be the one causing problems. I'm not sure if the wire is broken at the crimp up in the fuse box or the relay itself is bad, but I'm going to try the relay first. I did try cleaning all the contacts on the relay by scraping them with a knife. I didn't have any contact cleaner with me, so just made due with what I had. I can't tell if it made any difference. It is a pain not having it at home to work on. The bike seems to have the problem much less now, but I didn't ride it very far, and still don't want to try to ride it home yet. Login or Register to Remove Ads
	0

01-05-2012, 06:12 PM	#14
Meme Member Join Date: Oct 2009 Location: Reno NV Posts: 57	Re: Bike dies/won't start. Electrical problem. Well, the local Suzuki shop doesn't have the relay in stock, and it's $85, for a part I might not need. This is frustrating to say the least.
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01-05-2012, 07:45 PM	#15
Gz Rider Senior Member Join Date: Aug 2011 Posts: 852	Re: Bike dies/won't start. Electrical problem. ... __________________ *Alert - This person is a douche. Use these comments and advice at your own risk* Login or Register to Remove Ads
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01-06-2012, 10:44 AM	#17
Gz Rider Senior Member Join Date: Aug 2011 Posts: 852	Re: Bike dies/won't start. Electrical problem. ... __________________ *Alert - This person is a douche. Use these comments and advice at your own risk*
	0

01-06-2012, 11:11 AM	#18
mrlmd1 Senior Member Join Date: Jan 2008 Location: Crawfordville, Florida Posts: 2,853	Re: Bike dies/won't start. Electrical problem. If the turn signals work, then how can the flasher be the problem? That makes no sense. If you had a short somewhere, you would be blowing a fuse. Sounds to me like you have a loose battery connection intermittently losing all power to the bike. Did you check and/or clean the connections at the battery terminals?
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01-06-2012, 11:52 AM	#19
Gz Rider Senior Member Join Date: Aug 2011 Posts: 852	Re: Bike dies/won't start. Electrical problem. ... __________________ *Alert - This person is a douche. Use these comments and advice at your own risk*
	0

01-06-2012, 02:41 PM	#20
mrlmd1 Senior Member Join Date: Jan 2008 Location: Crawfordville, Florida Posts: 2,853	Re: Bike dies/won't start. Electrical problem. I disagree - a short big enough to stop the bike dead would certainly blow a fuse. That's why, being an intermittent problem, it is much more likely to be a loose connection somewhere in the line from battery to the plug. Start at the battery and go through the whole system 'till you find it and you will need the wiring diagram on here to help trace the ignition system. It could even be a dirty or loose connection from the wire at the plug on the other end of the line. Is the plug wire pushed/screwed all the way in to the connector cap on the end, the one that clips on to the plug? If the turn signals still work when the bike won't turn over, that sort of eliminates a bad battery connection (but you should check it anyway), and limits your looking to the entire path through the ignition system, including all the kill switches, for a loose connection somewhere.
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