Join Date: Nov 2010
Location: San Francisco, CA
X-country ride on-the-road emergency: electrical problems! Any advice appreciated!!
I'm going to try to be as detailed as possible but I'm broken down in Vancouver, BC (from San Francisco, CA) at the moment and I need to get to the Wee to the airport TODAY in order to ship it and myself to Germany via non-refundable reservations! :\
I spent several weeks having the bike overhauled for a long trip across Europe and only in the last three weeks or so I've started having major electrical issues. It started out with headlights failing on a long ride but other things on the front of the bike working fine. Mechanic did some troubleshooting and replaced the 7-pin wiring harness in the nose of the bike with a new and more heavy-duty 9-pin. Note that this would NOT be the harness located behind the radiator that has given people on this forum troubile. Also, I cleaned and reassembled the starter switch. Replacing the wiring harness in the nose seemed to have resolved the electrical issues until yesterday.
I was stuck in a parade in Seattle yesterday and forgot to turn the 2nd headlight off while idling. At one point I ended up parking the bike and when I tried to restart it didn't have enough juice to turn over. Ended up getting a jump from AAA and then immediately took off and rode the rest of the way to the US/CA border. Everything seemed fine.
I was stuck in another traffic snarl at the border and I don't remember whether or not I turned the 2nd headlight off while in queue but everything seemed fine until about 10 miles out on 99 north of the CA border. Hit the turning signal and the engine cut out. When I released the signal it came back on and I tried the signal again but this time the engine cut out and did not come back on. Pulled to the side of the road and didn't even have enough juice to turn it over but all of the lights and gauges etc worked. Ended up getting towed into a Suzuki service center in Vancouver. Unfortunately, they are not open on Monday. :\
I'm about to run to the hardware store to pick up some lightweight auto jumper cables in the hopes that I can at least get the bike started, cleaned up, and to the airport in time to make the customs cut-off. Thinking that I might have to ship a dead bike to Europe and then deal with this when I arrive in Munich. Best case scenario is that I will be in Italy for about a month so maybe I can continue to jump the bike and make a mad run from Munich to Cesena and with a little luck (and as little lights and accessories as possible) make it to Cesena and see if I can find a shop while I'm there.
The wiring on the bike is stock OEM except for two things: The previous owner installed a Power Commander. Not sure where that taps in. Also, there is a secondary fuse box under the seat the has a relay that is tapped into the right-hand side headlight. I need to double-check but I think the Stebel horn, maybe the grip warmers, something Power Commander, and an in-dash red-yellow-green charging status LED are hanging off of that secondary fuse box. I mention that only in the case where someone might think there is a short. I don't think any of those things should be much of a draw except the warmers and I wasn't using them at the time of the breakdown. Unfortunately, my GPS mount was blocking my view of the charging LED so I don't know the state of the charging system up to the breakdown.
Oh, and finally, I just replaced the battery like 3 week ago.
Any advice would be greatly appreciated. Hell, if there is a Trooper in Vancouver who might be able to assist with a trailer to get me to the airport in the worst-case scenario that would be AMAZING!
Thx, guys! I'll do my best check on on this thread but it's going to be hectic today!
Last edited by nrvale0; 06-27-2011 at 12:32 PM.