Electrical gremlins- Suzuki GT185.....what to check next ?

[joeloss1]

Sudden electrical fault yesterday....I was re-fitting tacho bulbs and starter/electrics died over a few start-ups then went completely dead.

I have.....recharged battery (although I believe was ok), checked main fuse/tried another, all bulbs are good, no loose connections inside headlight or under side-cover that I can see......dead as a dodo.
I don't as yet have any electrical testing equipment.....guess I should get some.

Any suggestions on what else to check gratefully received.

John (Worthing,UK).

[jabcb]

If the problem is related to the work you just did, then you may have a wire that has backed out of one of the electrical connectors in the headlight bucket. It happened often enough that Suzuki addressed it in Service Bulletin General-4.
See: http://www.ozebook.com/compendium/techb ... %201-9.pdf
Check the multi-wire connectors in the headlight bucket to see if any backed out of the connector.

Your bike has a starter/generator. It doesn’t have an alternator.
Wiring diagram: download/file.php?id=827

Having multiple problems at the same time on vintage bikes happens a lot. The starter problem may be unrelated to the work you just did.

Check the battery voltage when you operate the starter.
If it doesn’t change much, then the starter relay is a likely culprit.
If it drops too much, then the battery might be shot. A battery can show good voltage without a load but be unable to produce enough current to run the starter.

[joeloss1]

Ok....many thanks....I'll check connections again. There are no electrics at all at the moment....everything dead.
I charged battery overnight....was still charging after approx 12 hours.....maybe a dead battery ? although it sparked away when I accidentally brushed fuse clips.

John.

[joeloss1]

Just had battery checked at bike shop.....all good so I guess it must be a connection somewhere.....where to start ?

[joeloss1]

Yipee ye ! Fixed. Sprayed contact cleaner in ignition switch connector box.....what's next I wonder ?

[joeloss1]

Oh no it wasn't fixed ! Thanks Jabcb......connectors moving out of box (ignition) inside headlamp shell.....keep doing it so maybe a pattern replacement or a bit of araldite on old one ?