I got a Suzuki across from the Gold Coast abandoned vehicle auction for $110, it had been stripped of its fairings and other bits and pieces, but i would like the challenge of putting it back together. I have checked the compression and it seems ok and at lest the motor turns over. I have changed the spark plugs and oil and put fresh petrol in. However the wiring has had some work do to it and that is my first challange. As you can see the wiring coming out of the starter relay does not look right. the orange and green wire carries a charge ok but when i connect the black and white wire the 30a fuse blows. any suggestions as to the possible problem.
What a great little project. I am always surprised at what nasty stuff some previous owners do to bikes.
I have sorted out Peter with a replacement harness and solenoid , hopefully his next post is the bike starting
Many thanks Chris, the harness was a challenge but the bike is now turning over without any blown fuses however there is still no spark and the petrol pump is not working, I will check both tomorrow
Okay, check your impedance on the pickup coil, also check and make sure you are seeing 12v at both of the ignition coils. the fuel pump is a 12v unit , you can power it directly from a battery to verify it is working , it could be a dodgy relay also keep at it mate , won’t be long and you will have it purring
Thanks Chris, checked the impedance on both coils, left hand side was 3.7 right hand side was 3.6, there was connectivity between the coils and spark plug but no power. The fuel pump did not work with the direct connection to the battery, I dismantled it and cleaned the connectors but still dead, again no power detected going into the pump, so there could be a problem with how I have connected everything up, I will take photos for you to check. If it is ok with you I would like to take the coils, ignitor and pump off the bike and bring them over for you to view and if faulty we can replace, if you think there is any other part that needs checking I can bring those too. Again many thanks for your help its much appreciated. Peter
I got the petrol pump turning over this morning but still no power to it, could the problem be in the harness, as one of the fuse inlets has no power to it also, all the fuses are new and test out ok. The igniter has power going to it but none coming out. I will bring the igniter tomorrow for you to test and replace if you have one and do you have another harness I can try? Peter
Yahoo, the motor started and ran for about a minute then stopped and the starter motor would not kick over after that. But good progress many thanks to you Chris. I will keep working at it but would like to know why the starter motor would not turn could the motor have seized?
I put it in gear and can move the motor so it's not that, could be the battery I will let it charge overnight
Nice work, once you get it running again, then pop your multimeter on the battery and check your voltage at idle and at 5000rpm , helpfully your stator is charging your battery
Starter motor turned over with direct charge and motor turn in gear, suspect the starter motor relay may have spat the dummy
Put a new starter relay in and it started first kick with a squart of start you barstard but only run for a few seconds. Now stripping the carburettor. All good fun
Cleaned the carburettor gave it a squirt and she runs, no smoke just a lovely rumble. Now over to Chris for fairings, seat etc
No... spoke to soon, the clutch seems stuck, the rod going into the clutch seems very firm (no movement) any ideas anyone??
Pop off the clutch cover and remove the pressure plate/springs. Operate the clutch lever and see if you get any movement. The plates could be stuck either due to age, dry from lack of oil or any other reason. Careful with the gasket on the cover if you want to save it, otherwise buy a new gasket.
I checked the clutch plates all ok, good movement throughout, the clutch cable was seized, I freed that but it seems too long by some 3 inches, I would not be surprised if it was the wrong one for the bike also the clutch lever adjustment is missing. Another visit to Chris is in order