Exploded view of Starter switch 2004 DL650 - Stromtrooper Forum : Suzuki V-Strom Motorcycle Forums
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post #1 of 9 Old 10-03-2010, 06:17 PM Thread Starter
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Unhappy Exploded view of Starter switch 2004 DL650

You guessed it. I took it apart and now it won't go back together. The starter switch I mean.
Tried to start on Saturday heard a quick spin up of the fuel pump and the dials, touched the starter button, heard a loud pop, suspected a main fuse. Read on this forum that might be casued by melted switch so decided to check that out. Found it moist and possibly it is the culprit. Cleaned it up and now wow what a jigsaw... any hints or an exploded view ? or photos? A previous article did have some photos but they appear to be no longer available.
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post #2 of 9 Old 10-03-2010, 11:26 PM
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Just took photos- Hold on it's coming in a few minutes 2005 model DL650

Found another thread with a few photos. you need some sort of grease for the starter contacts to slide back and forth. dilectric grease?

Another thread with a couple of photos, the previous thread you mentioned that used to have photos was for a later year. I'll post my photos for future reference there too

https://www.stromtrooper.com/maintena...tml#post614181

I didn't write this guide. It magically appeared. You didn't read it. Knightstrom didn't write it. Knightstrom doesn't endorse it. In fact, YOU wrote it.

If you don't agree that you wrote this guide for your own use, do not follow this guide.

If you agree that you wrote this guide for your own use, and your Strom doesn't work after following this guide, its your fault.

Last edited by knightstrom; 10-03-2010 at 11:29 PM.
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post #3 of 9 Old 10-03-2010, 11:51 PM
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I didn't completely disassemble as I did the same thing and didn't have any reference . I had to push start into a dealer and have them figure it out. ( I was traveling when I decided to undertake this and got frustrated.

Photos are in order of removal so start at bottom









Note the top brass piece rest on top of the bottom one- They are not interconnected- that was where I got hung up trying to reassemble and got flustered. Also a little (Dilectric?) grease needs to be used where the contacts slide allowing the spring to push the button back out.




Hope this helps

I didn't write this guide. It magically appeared. You didn't read it. Knightstrom didn't write it. Knightstrom doesn't endorse it. In fact, YOU wrote it.

If you don't agree that you wrote this guide for your own use, do not follow this guide.

If you agree that you wrote this guide for your own use, and your Strom doesn't work after following this guide, its your fault.
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post #4 of 9 Old 10-04-2010, 01:04 AM Thread Starter
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Mate you are a champion. I actually mangaed to get the thing back togethe and it seems to work okay.... However I've now checked the 30 amp fuses.. all okay!! All the 10 and 15s are okay also. Still everything electrical is dead. Except the clock which shows 1.00pm after i reconncect the battery which I have charged to 12.7 volts...

Igntion switch packed it in??
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post #5 of 9 Old 10-04-2010, 08:21 PM
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I don't think so.

Did you check your kill switch?

It's on top of the start switch housing. My guess is, it got tripped to the "off" position while you were wrestling with the start switch maintenance.

2007 DL-650 (I gave away in 2012 with 111,000 + miles)
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post #6 of 9 Old 10-05-2010, 12:13 AM Thread Starter
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Yep. Thanks for that. But still no good. Absolutely nothing... I started another thread on DL650 specific.
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post #7 of 9 Old 08-27-2011, 11:53 AM
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Thanks!

First, thanks a lot for this thread. It totally saved me.

Secondly, I'm sure it's a mute point, but just incase anyone else has the same issue, my starter also didn't work when I put it back together.

I noticed when I was putting the two pieces of the housing back together on the bar that there is a sweet spot where the housing seems to fit together closer then if you were to rotate it a bit. Of course I ignored it and rotated the whole housing upright a bit. It was damn close, but it didn't seem to fit together quite perfectly. Everything looked right. The lights were fixed, and they would go off when I pressed the starter, but it still didn't turn over.

I took the to halves apart again (but not the small parts inside, just the two main parts), and put them back together in the sweet spot, and now it starts.

I'm guessing that perhaps something was grounding the kill switch?

Anyway, I hope that helps somebody as much as this thread helped me.

Thanks,
NEIN

Last edited by Ninetynein; 08-27-2011 at 11:56 AM.
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post #8 of 9 Old 08-27-2011, 12:03 PM
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The 2004 switch is a bit different from later models. It doesn't have the normally closed contacts that turn off the headlights when the button is pressed.

Pat- 2007 DL650A was ridden to all 48 contiguous states. I didn't quite make it to 17,000 miles on the 2012 DL650A.
Nicknames I use to lessen typing, Vee = 2002-2012 DL1000s. Vee2=2014-2016 DL1000s. Wee = 2004-2011 DL650s. Glee = 2012-2016 DL650s
See https://www.stromtrooper.com/general-...nicknames.html

Please vote in the poll on what Strom(s) you have at https://www.stromtrooper.com/informat...-you-have.html
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post #9 of 9 Old 06-15-2014, 07:04 PM
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This is an old thread but it helped me this weekend with my K5 that was having starter issues. I had printed out Black Lab's handy guide but when I opened the housing, hey, it's different. I took it apart anyway (not paying enough attention) and cleaned everything up, added some dielectric grease and put it back together. That's where the not paying enough attention comes in, but I puzzled it out and these pics helped a lot. Before I mounted it to the handlebar, I tried it and nothing happened. Great discouragement. Came in here and started looking for starter motor connection posts and related items and it dawned on me--I didn't pull the clutch in when I tried starting it. DOH! Ran back out and pulled in the clutch and it fired right up.

Yeah, I know, the Eastern Beaver relay thingies will keep this from being a repeat. I need to look into those.

But in the meantime, thanks!
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