SuzukiSavage.com - Bike died on the way to work this morning

springman Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 2246 Spring, Texas Gender:	Re: Bike died on the way to work this morning Reply #15 - 06/30/19 at 16:03:14 Thanks guys. The tank is off. I just replaced spark plug while I was there. I will inspect the wire one more time and if I do not find a bad wire I will disconnect and reconnect one by one. I keep my bike key separate so it is basically just the key that goes into the switch.
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springman

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Re: Bike died on the way to work this morning
Reply #16 - 06/30/19 at 17:01:31

Help. I used JOG's method and found that the red wire shown on the picture currently disconnected is the one that blows the fuse. Preliminary examination does not show the issue. Recommendations gladly accepted. It will be getting dark soon so I will probably call it quits for today shortly. Thanks for the help guys. Thanks JOG.

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springman Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 2246 Spring, Texas Gender:	Re: Bike died on the way to work this morning Reply #17 - 06/30/19 at 17:26:00 Well, I give up for tonight. I think the snow cone place closes at 8 which means I better get my butt in gear for my Bahama Mama.
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Re: Bike died on the way to work this morning
Reply #18 - 06/30/19 at 18:23:30

This is just general info; however, if it were me I would get out my Clymer manual and start review the circuit patterns. I would also look for rub sports on wires, rust / corrosion on connectors, so on. I would give attention to the kill switch circuit and the wires going to the ignition coil. I can't remember off the top of my head, other than the side stand are their any other safety features on an S40? Good luck.

Best regards,

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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28996 L.A. California Gender:	Re: Bike died on the way to work this morning Reply #19 - 06/30/19 at 19:35:08 I think that big red wire is the main battery coming off the starter relay. Yep, pull that and short problems are over.
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springman

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Re: Bike died on the way to work this morning
Reply #20 - 06/30/19 at 19:47:14

Thanks pg. I do not have the Clymer manual. I looked for cuts of frays in the wire but did not see anything. I think once I get back to it I will work from the battery up. If the problem is not between the battery and the starter solenoid it looks like I will have to cut the tape holding the wires together so I can follow that wire. Not looking forward to that.

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Re: Bike died on the way to work this morning
Reply #21 - 07/01/19 at 03:26:02

Here is the wiring diagram.

http://suzukisavage.com/cgi-bin/YaBB.pl?num=1294779818

I believe the red wire with the connector carries the power forward on the bike....the red wire to the relay does not have a connector (just terminal ends).

I would disconnect the wiring connectors under the tank, then plug the red wire back in and see if the fuse blows. If not....start plugging them back in and until you find the one that blows the fuse.

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pg

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Re: Bike died on the way to work this morning
Reply #22 - 07/01/19 at 04:00:38

Springman, I wouldn't open up any of the wrapped wires just yet. My suggestion is a means to start trouble shooting anything that doesn't look appropriate. A little corrosion in a connector can cause some significant problems, a pinched wire a can do some funny things as well. I'm afraid it is not an easy task to find the problem.

Best regards,

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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Bike died on the way to work this morning Reply #23 - 07/01/19 at 04:13:36 Don't do anything radical yet. Work forward with disconnecting and as someone else said, plug the red wire back together, Did you check out the wires near the steering stop Have you done ANY work on the bike recently, before this started?
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springman

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Re: Bike died on the way to work this morning
Reply #24 - 07/01/19 at 09:51:25

Yep, that wire is coming from the starter relay. I see the error of my ways. I will disconnect all connectors again, and connect the red wire connector first (this was my mistake, that was not the first one I connected) and keep connecting things until fuse blows. I guess I better pick up some more fuses as I only have 2 left out of the pack of 5.

Dave, I did find the diagrams last night and pored over them for a while. I am not sure I understand just how to read the diagram (actually I am concerned that I do understand it and if so I could have a real mess on my hands).

I won't do anything radical yet. I will probably look for a primer on youtube on how to read electrical diagrams.

Thanks all!

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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28996 L.A. California Gender:	Re: Bike died on the way to work this morning Reply #25 - 07/01/19 at 10:00:40 There's a cheaper way to do this. Take a 12v light and hook it up to where the fuse goes. When the light is lit, you have current rather than a burnt fuse. Harbor freight also has a meter that plugs in the fuse receptacle.
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springman Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 2246 Spring, Texas Gender:	Re: Bike died on the way to work this morning Reply #26 - 07/01/19 at 11:24:23 Versy, the light will tell me there is current, but it won't tell me if it exceeds 20 amps. Or am I not understanding?
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springman Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 2246 Spring, Texas Gender:	Re: Bike died on the way to work this morning Reply #27 - 07/01/19 at 11:39:34 quick question. On the diagram, when 2 wires are connected by a black dot, does that mean those 2 wires are connected at that point? Actually if I look at diagram more closely it says just that, so nevermind.
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Re: Bike died on the way to work this morning
Reply #28 - 07/01/19 at 12:03:57

springman wrote on 07/01/19 at 11:24:23:

Versy, the light will tell me there is current, but it won't tell me if it exceeds 20 amps. Or am I not understanding?

It would if it burned brightly.

I haven't read thru, but several places where wires get abused.
the headlight were the wires run thru the hole.
the pigtail that connects the tank.
wires along the frame under the tank.

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springman Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 2246 Spring, Texas Gender:	Re: Bike died on the way to work this morning Reply #29 - 07/01/19 at 12:14:28 Thanks Versy.
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