Ignition switch connector damaged.

[Shawthing]

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.

[yorkie_chris]

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.

[DarrenSV650S]

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

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:






Dropped forwards:







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









This one....?




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




hopefully youll get it sorted mate..

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

[CodeJACK]

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.

[yorkie_chris]

Most of current is from headlights

[Shawthing]

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.

[Nobbylad]

Does that mean it's now out of warranty?

[Shawthing]

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!