• Required reading for all forum users!!!

    Welcome!
    Register to access the full functionality of the GSResources forum. Until you register and activate your account you will not have full forum access, nor will you be able to post or reply to messages.

    A note to new registrants...
    All new forum registrations must be activated via email before you have full access to the forum.

    A Special Note about Email accounts!
    DO NOT SIGN UP USING hotmail, outlook, gmx, sbcglobal, att, bellsouth or email.com. They delete our forum signup emails.

    A note to old forum members...
    I receive numerous requests from people who can no longer log in because their accounts were deleted. As mentioned in the forum FAQ, user accounts are deleted if you haven't logged in for the past 6 months. If you can't log in, then create a new forum account. If you don't get an error message, then check your email account for an activation message. If you get a message stating that the email address is already in use, then your account still exists so follow the instructions in the forum FAQ for resetting your password.

    Have you forgotten your password or have a new email address? Then read the forum FAQ for details on how to reset it.

    Any email requests for "can't log in anymore" problems or "lost my password" problems will be deleted. Read the forum FAQ and follow the instructions there - that's what we have one for...

  • Returning Visitors

    If you are a returning visitor who never received your confirmation email, then odds are your email provider is blockinig emails from our server. The only thing that can be done to get around this is you will have to try creating another forum account using an email address from another domain.

    If you are a returning visitor to the forum and can't log in using your old forum name and password but used to be able to then chances are your account is deleted. Purges of the databases are done regularly. You will have to create a new forum account and you should be all set.

GS 550 Ignition fuse blows at key-on

  • Thread starter Thread starter Chris15379
  • Start date Start date
C

Chris15379

Guest
This bike has been sitting about a year. When I turn the key on, the ignition fuse at the starter solenoid blows instantly, everytime. the wire on the battery cable side of the fuse seems good, its the other side that has continuity to Ground. Does anyone know where the other end of this wire will be? Figured I was better checking on here than taking stuff apart to try to trace wires right away. I imagine the wire must go to the ignition but does it tie into anything else along the way that I could take a look at?

Thanks
 
I should also mention its a 1978. Ive owned a few suzukis of this era good to see theres a forum for them, never even thought to look for one before today
 
Thanks, I would guess your talking about a Voltage regulator/rectifier? Where is it on these bikes?
 
if you look at your manual it will show you what it looks like and where it is located.
 
I dont have a manual. But I did manage to get off my butt and go out to the garage and look at the bike. I found the regulator right by the starter solenoid. But after blowing 6 fuses and checking different things, I found that the bike is fine with the key on as long as the kill switch is in the off position. I did manage to get it cranking and it started to sputter but then blew the fuse. So the problem now is the bike will turn on, all lights function and whatnot as normal, but right when I put the bike on "run" the fuse blows
 
You can go to Basscliff's website for free manual downloads.

http://members.dslextreme.com/users/bikecliff/

Sounds like you have a short in the ignitor; unplug it and see if it disappears. of course it will not run? Wait you probaly have points unless someone swapped in a Dyna-S. Check under the right hand cover to see what is there.

Disconnect it , unless points then look for a wire rubbing somewhere to ground. Pull the tank and have a look starting at the handle bar back to the fuse box.
 
I downloaded the manual. Ill have to get a better look tomorrow. I pulled the tank off and looked at all the wiring under there, didnt see anything touching metal. I moved all the wires around. when I turn the switch to "run" the Orange wire coming from the kill switch gets warm before the fuse blows, other 2 wires stay cool.
 
Chris15379 said:
I downloaded the manual. Ill have to get a better look tomorrow. I pulled the tank off and looked at all the wiring under there, didnt see anything touching metal. I moved all the wires around. when I turn the switch to "run" the Orange wire coming from the kill switch gets warm before the fuse blows, other 2 wires stay cool.
Click to expand...

Bad sign, Just to be sure, check your coils to see if you have 3-4 ohms. If one shorted and had say only 1 ohm then it would pull much more current.
 
Thanks for the help. Your saying to disconnect the 2 leads coming off of each coil, and check resistance across the 2, looking for 3-4ohms? Also what are you thinking it would be if the coils check out ok? Looking at the the wiring diagram it seems like the orange wire goes all over the place. One thing worth mentioning, for the couple times I was able to get the bike to turn over, with the kill switch on "run" and it started to sputter, I had the right side plug out, connected, and sitting on the head. The bike was sputtering but the plug that was out wasnt sparking at all
 
Last edited:
Chris15379 said:
Thanks for the help. Your saying to disconnect the 2 leads coming off of each coil, and check resistance across the 2, looking for 3-4ohms? Also what are you thinking it would be if the coils check out ok? Looking at the the wiring diagram it seems like the orange wire goes all over the place. One thing worth mentioning, for the couple times I was able to get the bike to turn over, with the kill switch on "run" and it started to sputter, I had the right side plug out, connected, and sitting on the head. The bike was sputtering but the plug that was out wasnt sparking at all
Click to expand...

I'm thinking you should look under the cover and see if you have points to a dyna S or some other ignition installed..........
 
20150419_100800.jpg hopefully this works. I assume this is thr points ignition? Never worked on one before. Never had a bike or car old enough
 
I completely disconnected the coils and removed them. Problem still occurs so I assume they arent the issue. Is there a way to bypass the kill switch to rule the switch itself out?
 
If you've disconnected both coils then my guess would be a harness or melted connector issue. Remove the tank and inspect all along the main harness. There are three connectors along the path from the coils to the emergency cutoff switch. Two connectors are right at the coils and one is under the tank. Look for any abrasions along the harness as well. You're tracing the path of an Orange/White wire.
 
I also checked the coils, had 3.5-4 ohms on both. Ill take a closer look at the harness, wish there was another way to narrow it down
 
Last edited:
Chris15379 said:
I also checked the coils, had 3.5-4 ohms on both. Ill take a closer look at the harness, wish there was another way to narrow it down
Click to expand...

I thought you could feel your wires getting hot? If the wire is cold there is no current ==> where the heat stops is the short.
 
Yes thats how I figured id find it, but I cant follow the wire after it goes into the tape/loom right under the front of the tank, havent found where it comes out on the other end of the bike, and really didnt want to have to disconnect everything and start unwrapping the wire harness
 
Last edited:
Chris15379 said:
Yes thats how I figured id find it, but I cant follow the wire after it goes into the tape/loom right under the front of the tank, havent found where it comes out on the other end of the bike, and really didnt want to have to disconnect everything and start unwrapping the wire harness
Click to expand...


Hint: if the wire is wrapped in a harness with multiple wraps of tape it is highly unlikely that is where the short it. Either it is cut (and obvious by inspection) or a melted connector or something is installed..
No need to rip the harness apart, although some disassembly is worth pursuing.
 
Follow the wires that come out of the right hand control (Start and Kill switch) and see where they connect into the main harness. Most likely it going to be a melted connector. Also take a close look along the entire main harness from that connector to the coils and see if you can spot something abraded or melted.
 
You must log in or register to reply here.
Back
Top