Check battery condition, connection, cables, and have load-tested. Often a failing battery will act like what you describe.Out for a ride and after a short stop at a photo op overlook the bike would not start. Everything comes to life as expected when the ignition key is turned on, lights, fuel pump primes etc. Hit the started and there is no click from the relay, the lights dim but the starter does not work. Was able to jump start the bike and get home. Once home I jumped the terminals of the relay and the bike started right up. This morning I pulled the relay and got out the shop manual. On the bench the stinkin’ thing clicks when 12V is applied, there is continuity across the terminals to the starter when 12V is applied and there is the correct resistance the terminals for voltage per the manual. Next I disassembled the starter button/switch which is a bit of a Rubics Cube. It’s now cleaned and back in place but the bike still reponds the same way, no click and light dim. Any thoughts? I have a new relay on the way and am hoping I didn’t order something that is not needed or going to work. Thanks in advance for any guidance.
Starter Relay Has Me Baffled - Bike Won’t Start
Out for a ride and after a short stop at a photo op overlook the bike would not start. Everything comes to life as expected when the ignition key is turned on, lights, fuel pump primes etc. Hit the started and there is no click from the relay, the lights dim but the starter does not work. Was able to jump start the bike and get home. Once home I jumped the terminals of the relay and the bike started right up. This morning I pulled the relay and got out the shop manual. On the bench the stinkin’ thing clicks when 12V is applied, there is continuity across the terminals to the starter when 12V is applied and there is the correct resistance the terminals for voltage per the manual. Next I disassembled the starter button/switch which is a bit of a Rubics Cube. It’s now cleaned and back in place but the bike still reponds the same way, no click and light dim. Any thoughts? I have a new relay on the way and am hoping I didn’t order something that is not needed or going to work. Thanks in advance for any guidance.
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Check battery condition, connection, cables, and have load-tested. Often a failing battery will act like what you describe.
The battery would not start the bike when the relay is jumped in that case I would think.Check battery condition, connection, cables, and have load-tested. Often a failing battery will act like what you describe.
Yup, and that is why we check those things first, because many have been where you are but fail to check/confirm the most obvious issue which is connectivity. A weak connection, corroded cable or terminal, poor ground will all allow a relay to click without necessarily providing enough voltage to start consistently. A load-tested battery is a known good, recently loosened, cleaned and protected terminals are a known good.
After the failed battery evidences itself, often times there is another electrical issue that becomes apparent. The ignition switch is known to corrode and provide an intermittent start, no-start condition.
The stator on this vintage Suzuki can burn out and cause similar issues.
Clutch switch and kickstand switch (as well as kill switch inadvertently left in wrong position) can also be suspect.
After the failed battery evidences itself, often times there is another electrical issue that becomes apparent. The ignition switch is known to corrode and provide an intermittent start, no-start condition.
The stator on this vintage Suzuki can burn out and cause similar issues.
Clutch switch and kickstand switch (as well as kill switch inadvertently left in wrong position) can also be suspect.
Should have made clear that I checked and cleaned, though nothing seemed to need cleaning, the battery terminals and the connections at the relay. The battery measures almost 13V just sitting in the bike and is about a year old. The clutch lever safety kill works and if it was shorted out I’m at a loss as to why the bike would start when it is bumped or the relay is jumped. Same is true with the kickstand safety kill.
Seems that power is getting to the starter when the relay is jumped which I’ve done four times during my diagnostics. The bike was bump started twice yesterday when it first failed and started without hesitation so things like kickstand, clutch and ignition switches seem, by my understanding, unlikely to be the issue. Guess when the new relay arrives that will answer the question of it being the problem.
Seems that power is getting to the starter when the relay is jumped which I’ve done four times during my diagnostics. The bike was bump started twice yesterday when it first failed and started without hesitation so things like kickstand, clutch and ignition switches seem, by my understanding, unlikely to be the issue. Guess when the new relay arrives that will answer the question of it being the problem.
Pretty much. You've done all the diagnostics to point to the relay as the problem.Guess when the new relay arrives that will answer the question of it being the problem.
I had a similar thing start to happen on my 14 1000 - would need to hit the starter button a few times before the starter motor turned. I had a replacement relay off a 250 Burgman scooter (Suzuki ran the same relay on a heap of bikes). Plugged it in and problem solved. Put the DL relay in the Burgman and the problem moved there which confirmed the issue.
These relays are all solid state nowadays compared to the older mechanical solenoid types and can do weird things when they malfunction.
Not an authority, but two observations:Once home I jumped the terminals of the relay and the bike started right up.
- I've had similar symptoms, and the starter relay was at fault (on a Gen 1). It's not common, but it happens. However:
- I think there's a post from Greywolf around here which explains that jumping the starter relay also bypasses the other interlock/safety switches, such as clutch and sidestand; so
- this test may not be conclusive.
Or I could be totally wrong.
This type of relay is pretty cheap - under $15 on eBay.
Suzuki used the same one on loads of models:
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Suzuki used the same one on loads of models:
Starter Relay Solenoid Suzuki Intruder Marauder Katana Burgman SV650 VZ800 VL800 770338827654 | eBay
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Check the clutch switch.
Could be the wires are off, the clutch leaver is not activating the switch or the switch is bad.
Join the switch wires as a test, if the bike starts every time that is your problem.
If your bike is built after 2007 you can't leave the wires joined but you can do it as a test.
Could be the wires are off, the clutch leaver is not activating the switch or the switch is bad.
Join the switch wires as a test, if the bike starts every time that is your problem.
If your bike is built after 2007 you can't leave the wires joined but you can do it as a test.
Mine did the same eBay $10 relay fixed it. Mine is a ‘13 and has the original battery by the way. Trying to get 10 years out of it lol.
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