Ignition switch connector damaged.
 

So i come out of work today . Turn on th ignition and Bike is dead.
Talk about DeJaVu moment.
Well actually this has happened to me before.
Bike went back to dealer 6 wks ago for same thing and thy claimed it was a loose connection.
This time we got it stripped down to find this (see pics)
Same as other pics i have found posted of this fault by other users of this and SVrider sites.

Question.
Is there a Suzuki approved cure to this frequent fault on the SV that i can point the dealer to, as it obviously was not cured last time. Bike is in warranty.

Re: Oh No Not Again.
 

Beyond making sure the connector is clean you're a bit buggered. You can fit relays to headlights to cut down on current a bit, not sure that is suzuki friendly.

Re: Oh No Not Again.
 

You'd be better replacing that connector. What is it for?

Re: Oh No Not Again.
 

i cleaned the connector and properly shoved it back together... sorted..


from my thread


The wires as they come from the bottom of the ignition barrel:

http://i860.photobucket.com/albums/a...g?t=1307726787




Dropped forwards:

http://i860.photobucket.com/albums/a...g?t=1307726792





Plastic housing moved and I assumed its the green 4 way connector I'm looking at??



http://i860.photobucket.com/albums/a...g?t=1307726805





This one....?

http://i860.photobucket.com/albums/a...g?t=1307726810


All looks fine, both male and female ends have no sign of melting or burning out...

http://i860.photobucket.com/albums/a...g?t=1307727021


hopefully youll get it sorted mate..

Re: Oh No Not Again.
 

its the dreaded green connector eh lol
Its a fairly comman known prob for the earlier (pre k5's) sv thous over on sv-portal
Thjeres lots of threads about it, and its an easy fix
You dont have to wait till it goes before you 'fix' it either

Re: Oh No Not Again.
 

I got this with my SV 650.

I pulled out all the melted plastic and stuck it back together and its been fine for 2 years now.
I did but an alternative connector from an on-line Auto electric shop but never got round to fitting it.

I think this is caused by water, weeping into the connector. there is a lot of current going through it during ignition so if you replace for another connector, make sure it can take big amps.

Re: Oh No Not Again.
 

Most of current is from headlights

Re: Ignition switch connector damaged.
 

Read abit more on SVportal.
So there is no real permanent cure from Suzuki, even when there are so many cases ( and owners put in dangerous situations when it fails)

With damage ( melting and oxidised terminals) to both connector sections it had to go.
But what's the warranty repair goin to be? I'd probably end up with a replacement green connector which is likely to fail on me at some point in the future.

I aint goin to let that happen to me again.

Only solution:- Cut out the connector and hardwire (soldered) ignition barrel wires to the loom, heatshrunk and electrical taped up.

Done.

Re: Ignition switch connector damaged.
 

Does that mean it's now out of warranty?

Re: Ignition switch connector damaged.
 

Only for any thing related to the green connector which i aint complaining about now.
Unrelated modification should not affect warranty.
There's only two months left anyway!