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SuzukiSavage.com
/cgi-bin/YaBB.pl General Category >> Rubber Side Down! >> ARRRGGG Won't start - SOLVED /cgi-bin/YaBB.pl?num=1164750768 Message started by SeeAPierce on 11/28/06 at 13:52:48 |
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Title: ARRRGGG Won't start - SOLVED Post by SeeAPierce on 11/28/06 at 13:52:48 All I did was replace the handlebars - honest! :-[ It started perfect 20 minutes earlier. I've changed the bars before without any problems. This time when I was done, the bike won't start... :'( All the switches work: turn signals, high beams, hazards. And the headlight goes out when I push the start button like it's supposed to ('06 model). But no decompression solenoid and no starter motor. dead dead dead. When I turn the ingnition key, I can hear the neutral relay engage and the neutral light goes on. I have pulled the seat and tank to check - everything is connected... ??? Does anyone have an exploded view of the right handlebar switch cluster? Even though the headlight goes out I'm afraid I've lost something in that cluster during the bar change... I've looked for step by step instructions on bypassing the neutral/clutch/stand system, but I can't find anything that's dumbed down to my level... :-/ |
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Title: Re: ARRRGGG Won't start Post by vroom1776 on 11/28/06 at 13:58:39 clutch interlock: rip off the two wires that go to the switch and solder them together, apply electrical tape. makes it think the clutch is engaged. Side stand relay is the same deal, I believe. Open up the left side switch housing and check everything in there... that is my best guess. Did you pull the tank off at all? you may have picnhed a wire... Oh, and! does the brake light work if you grab the front brake lever? if not, you may have disconnected that whole cable. The connector lives on the right side of the frame, kinda under the tank. you should be able to see it w/o removing the tank. Make sure this connector is fully seated. |
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Title: Re: ARRRGGG Won't start Post by SeeAPierce on 11/28/06 at 14:20:59 I did just that with the clutch wires - didn't help. I wasn't sure if the sidestand was the same, so I'll try that tonight. What else is in the left side switch housing that could affect starting? Brake light does go on when I pull brake lever. And that cable connection on the right seems to be together, but I'm going to pull it apart and re-seat it tonight...Thanks! |
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Title: Re: ARRRGGG Won't start Post by Reelthing on 11/28/06 at 15:00:38 check the fuses |
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Title: Re: ARRRGGG Won't start Post by vroom1776 on 11/28/06 at 15:38:51 I'm not 100% sure the side stand is the same. Take a look at the switch when the side stand is down and up. I THINK it pushes on the lever when it is down, so you'd want to make sure the circuit is open... I THINK! I will try to check a wiring diagram and check my own ride tonight. V |
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Title: Re: ARRRGGG Won't start Post by Ed_L. on 11/28/06 at 18:36:26 The kickstand switch is a on when pushed setup so when the stand is up it pushes on the switch. Just cut the wires, strip them and twist them together to bypass it. |
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Title: Re: ARRRGGG Won't start Post by SeeAPierce on 11/28/06 at 18:36:47 are there only two fuses? If so, they're both fine. Is there another? Thanks Reelthing wrote:
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Title: Re: ARRRGGG Won't start Post by SeeAPierce on 11/28/06 at 18:46:50 I've now bypassed the clutch and the sidestand switches. All other electrical connections seem to be tight and correct. All switches seem to work including the start button as evidenced by the headlight turning off when pressed. Bike is in neutral and neutral indicator is on. I'm wondering if the start button hits multiple contacts, and perhaps even though the headlights are dimming the connection to the starting system is shorted out or broken...? Ed_L. wrote:
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Title: Re: ARRRGGG Won't start Post by Ed_L. on 11/28/06 at 18:50:52 Here's another thing to check, there is a electrical connection under the right front of the tank on the main harness, check to see if it was yanked on while changing the handle bars. I pulled it loose on my '02 and it drove me nuts trying to figure out what went wrong. You can see it if you stand at the front of the bike and look along the top rail under the front of the tank. |
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Title: Re: ARRRGGG Won't start Post by SeeAPierce on 11/28/06 at 19:04:39 Yea - thanks Ed...I checked that as well...It seems to be together - that's the same connector that contains the front brakelight wires...and they work fine... this is driving me nuts!!! Ed_L. wrote:
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Title: Re: ARRRGGG Won't start Post by Ed_L. on 11/29/06 at 07:00:45 I've had the starter/turnoff switch apart on my bike, be carefull if you take it apart there are a bunch of little springs and ball contacts in it. Spread something out on the floor of the shop to catch whatever falls out. I found a piece of a bug stuck in the contacts on my bike so there is no telling what you could find. Can't think of anything else to check, it is probably something simple so keep looking and luck with it. |
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Title: Re: ARRRGGG Won't start Post by SeeAPierce on 11/29/06 at 07:05:57 That is exactly what I'm worried about, that something popped out...I took it apart again last night and checked all the contacts, and everything seems intact. I checked continuity through the switch to the connector, and everything seems to check out there. But I've learned over the years, that just because you have continuity doesn't mean you have the correct electrical path without shorts. I'm sure it is something simple that I just haven't found yet. Does clymers have an exploded view of the switches? Ed_L. wrote:
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Title: Re: ARRRGGG Won't start Post by Reelthing on 11/29/06 at 07:21:25 SeeAPierce wrote:
that's them - might want to check the battery voltage for >12.3 but your saying you do not hear the decomp sol click? |
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Title: Re: ARRRGGG Won't start Post by SeeAPierce on 11/29/06 at 09:49:58 That's correct - headlight shuts off, but decomp sol does not click...battery voltage is good @ 12+ Reelthing wrote:
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Title: Re: ARRRGGG Won't start Post by azjay on 11/29/06 at 10:37:56 i dont recall the headlight turning off when cranking occurs, what is the voltage on the battery when attempting to crank? do we have an electrical diagram on this web site? or else i'll look in the book when i get home this afternoon |
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Title: Re: ARRRGGG Won't start Post by Reelthing on 11/29/06 at 10:42:40 I think his '06 does that - seems to be some wireing changes on it |
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Title: Re: ARRRGGG Won't start Post by Savage_Rob on 11/29/06 at 10:50:12 Yeah, I think the 05 and 06 both have that feature to help cranking by cutting down on electrical load during starting. |
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Title: Re: ARRRGGG Won't start Post by vroom1776 on 11/29/06 at 11:05:21 05 and up models have a relay that cuts the headlight out when starting. The thread "that mysterious electrical system" in the tech sect has a wiring diagram... when cranking on pre-05 models. the headligth should dim when starting. You must have a short somewhere that is taking the starter out of the circuit, or, an open which is just cutting it all out... know how to use a DMM? |
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Title: Re: ARRRGGG Won't start Post by Reelthing on 11/29/06 at 11:09:31 creates a little bit of a problem with using older wire diagrams - wonder where they stuck in the relay to kill the head light when the starter button is pressed and which wire they are using as it seems to have power - is it inline on the Y/G wire (yellow/green stripe) - if so that maybe where the issue happens as it runs to the clutch switch. |
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Title: Re: ARRRGGG Won't start Post by SeeAPierce on 11/29/06 at 13:22:19 Yea - although I'm not really in my comfort zone with ohms law... 12volts, grounding, continuity I'm all over that stuff... Looks like I'll be spending some quality time with my meter over the weekend...between honey-doos... vroom1776 wrote:
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Title: Re: ARRRGGG Won't start - SOLVED Post by SeeAPierce on 12/09/06 at 13:58:06 Intermittent kill switch... >:( I was able to cut a small wedge of rubber to place between the switch housing and the black contact plate. This keeps the contact plate in contact with the rocker...and all is right with the world. Now I need to go back and re-connect everyhting I bypassed.... :P |
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Title: Re: ARRRGGG Won't start - SOLVED Post by PerrydaSavage on 12/09/06 at 14:37:44 ;D Glad to hear that ya got the Bike started Pierce! |
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Title: Re: ARRRGGG Won't start - SOLVED Post by azjay on 12/10/06 at 06:25:10 congratulations! that was a tough job well done! now you have become the newest harness expert! |
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Title: Re: ARRRGGG Won't start - SOLVED Post by SeeAPierce on 12/10/06 at 19:15:04 Thanks for all the help everyone! I certainly do feel a real bond with the wiring of the bike now! Everything is now back together and I even went out for a brisk (short and cold) test ride. Now back to the task I started...bar end turn signals... |
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Title: Re: ARRRGGG Won't start - SOLVED Post by Reelthing on 12/11/06 at 04:56:52 did you find where the headlight relay that turns it off with the start button is located? |
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Title: Re: ARRRGGG Won't start - SOLVED Post by SeeAPierce on 12/11/06 at 10:36:56 It's actually the start button that does the switching - there is no additional relay. The lighting power runs through the start switch...normally closed. When you push the button, the single set of contacts move from the lighting circuit (now open, so the lights turn off) to the start circuit (now closed to start the bike). When you release the button, the switch contacts return to their normally closed position in the lighting circuit, re-energizing the lights. |
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Title: Re: ARRRGGG Won't start - SOLVED Post by Reelthing on 12/11/06 at 11:11:12 Interesting - thanks |
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Title: Re: ARRRGGG Won't start - SOLVED Post by Steve530 on 12/11/06 at 15:10:07 So I guess if you wanted to upgrade an older Savage, you could just replace the switch and route the wires through the new starter switch. A relay seems like a better idea to me, though. |
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