Author Topic: Can't turn the bike off - Strange electrical problem (Read 3324 times)

Himself · « **Reply #20 on:** May 04, 2020, 17:55:56 »

Yes, you were correct - where it was smoking was the problem.

Never rebuilt a block connector before - every day is a school day.

Any advice or recommendations on which connector to buy from Amazon?

Or would it be better to go around the outside of the connector by crimping on bullet connectors?

Rusty Nuts · « **Reply #21 on:** May 04, 2020, 18:03:38 »

Bullets are inferior and would end up being massively bulky. Is the lug broken? If not, I'd photo the blocks, write the colour sequence out, remove, clean, replace all wires in both halves. Then cable tie a bit of inner tube round the connector - even use corrosion block grease first if you've got some.

Barbel Mick · « **Reply #22 on:** May 04, 2020, 18:15:45 »

Maybe something like this would do the job...............
https://www.ebay.co.uk/itm/NEW-4-WAY-PIN-PLUG-x-5-CONNECTORS-6-3MM-PIN-SOCKET-MOTORCYCLE-FITS-Suzuki/264692896141?hash=item3da0ed118d:g:KdcAAOSwJ4pd7kF-

You might have to lengthen one side of the wiring a little by soldering and shrink tubing a few inches of wire onto the existing wires.

Just had another look at the advert, you get 5 male & female plugs for that price so you could have a practice on your soldering if you thought you'd need it.

Brockett · « **Reply #23 on:** May 04, 2020, 18:30:29 »

Good luck with that one. I would make up a single connector but that's me and I muck everything up.
However... an "L6" three and a bit years old and you find that. I can't see me moving out of

any time soon. I wonder if the SV is any better. Now maybe the best time for me to have look.

tallpaul · « **Reply #24 on:** May 04, 2020, 18:46:00 »

If you could extract one of the good pins you can compare it with the ones in the link Mick posted. The correct crimping tool would make the best job of it too. I know with the correct terminals to hand and the right crimp tool it could be repaired to look as good as new. Your opinion as to how good it was when new is another matter!

Barbel Mick · « **Reply #25 on:** May 04, 2020, 19:07:55 »

Yeah, you can buy the connectors separately but they come in different sizes.

Himself · « **Reply #26 on:** May 04, 2020, 19:22:21 »

The broken spade connector is in there tight. I don't see it coming out any time soon. I can see and lift the tang, but it isn't moving.

Options are all four, cut out the existing plug and rebuild it, but I think I'll go with bridging just the broken wire around the plug as a next step and see where it goes after that.

Barbel Mick · « **Reply #27 on:** May 04, 2020, 19:24:21 »

If it was smoking it will have got hot enough to melt itself into the plastic.
Will the others come out, just to check they are OK and clean them?

Ianmc · « **Reply #28 on:** May 04, 2020, 21:08:00 »

With a bit of luck it might have just been steam as the bike had just been washed.

hotbulb · « **Reply #29 on:** May 04, 2020, 21:28:58 »

Maybe worth looking at some connector vendors such as...
https://kojaycat.co.uk/S-Wiring-Loom-Connectors

porter · « **Reply #30 on:** May 04, 2020, 21:35:05 »

This was what the recall was for, connect Suzuki Uk, email these pictures and hopefully they'll sort a new loom for you, I know the bike is 5 years now but worth a try.

V-Twin · « **Reply #31 on:** May 04, 2020, 21:49:16 »

"The correct crimping tool would make the best job of it too".
Also a good idea is to solder the wire to terminal as well as crimping.

user650 · « **Reply #32 on:** May 04, 2020, 22:52:13 »

Do a temp repair and check it's covered by the recall, link above, it should be valid still as it was a safety recall. Let Suzuki

have the fun

kwackboy · « **Reply #33 on:** May 05, 2020, 07:26:26 »

Himself....
Looks like you found your problem and there's some good advice on here as to a repair

As for the recall, I doubt I'd let a dealership strip down my entire bike to replace the whole loom for just one faulty connection.

Ianmc · « **Reply #34 on:** May 05, 2020, 08:46:20 »

“Maybe worth looking at some connector vendors such as...
https://kojaycat.co.uk/S-Wiring-Loom-Connectors”

This is a great find,I had no idea this company existed.

Himself · « **Reply #35 on:** May 05, 2020, 11:32:54 »

Thank you folks - great support from the forum.

I've bridged out the broken wire with a bullet connector. I tried covering the multiblock in an old inner tube but it wasn't going to work. Water would still have got in.

I ended up using silicone waterproofing spray and old fashioned PVC insulation tape to improve on the original. All of that gets me back on the road.

Now to call Suzuki and if that goes nowhere, there is an excellent Bike Alarm bloke who covers my area, so I'll ask him to help out with a decent repair.

One more photo of the finished repair to come

Barbel Mick · « **Reply #36 on:** May 05, 2020, 13:05:33 »

I recommend this stuff for your electric connectors.
Works for other stuff too.
https://www.ebay.co.uk/itm/ACF50-Anti-Corrosion-Block-Grease-454g-Tub/383531071064?hash=item594c3bb658:g:hXoAAOSwpB5eruPv

oslin · « **Reply #37 on:** May 05, 2020, 15:40:10 »

You can buy those block connectors in various sizes from ebay I bought various sizes for spares

Silverback · « **Reply #38 on:** May 05, 2020, 18:35:28 »

I've also used Kojaycat for electrical connectors, good service.

I had electrical issues with mine. Just buy yourself the correct crimping tool and replace connector (with a waterproof one) if possible. Think this tool is the one you want.
Look at this on eBay http://www.ebay.co.uk/itm/173910846131

Himself · « **Reply #39 on:** May 05, 2020, 22:03:14 »

I had an excellent conversation with Suzuki customer services today. According to the database a dealer has claimed for the recall work

However rather than leave it there, Suzuki asked for any photos I had, which they have passed to "technical" to see if the work has been done.

No idea where it will end up, but at least Suzuki are open to finding a solution.

I've started the rebuild and got to the point where I need that long 3mm hex key for the front carb rubber clamp. 30cm hex key is now on order - What a daft design.