Final electrical issues HELP!

[Coyote]

This is going to take some explaining, but I'll try not to write a book. There are 3 issues remaining. The first is the most perplexing. Tried everything today and can't find the fix.
With the right hand switch in the run position, the neutral light comes on with the key and goes off with the key. With the RH switch in the off position, neutral light comes on with key but stays on when you key off. There are several way to kill the light. Switching back to run, the light goes out. Operating either brake, the light goes off. Flipping the turn signal switch, the light goes off. In fact if you just jiggle the little plunger in the rear brake switch, the light goes out. I figured the problem was in the brake switch so I replaced it with a spare one I had. No change. Removed (unplugged) both brake switches from the equation, Light still stay on with the key off. Then we unplugged and replugged every connection on the bike. The weird problem remains.

Second issue is the panel light flashes on left turn but does not come on or flash on right hand turn The signals are flashing but the panel light is not. Left works correctly. Right works correctly, but no flashing panel light.

The third issue is there is no power to the horn. Horn works fine with test leads. Button acts dead.

I should point out that there are 2 wires left over in the HL shell. For the European front parking light the wires are brown and black / white which I assume is the ground. I have the brown wire but the other wire I have is orange with a female connector and has no mating wire.

[Coyote]

That spare orange wire has to do something. Checked between the orange wire and ground this morning. With ignition switched on, that wire shows full battery voltage

[jabcb]

Per the wiring diagram, you bike has two hot circuits presumably to reduce voltage drops.
download/file.php?id=824

One circuit powers the lights (except for stoplight): red from the battery to ignition switch, then orange from the ignition switch to the light on/of switch.

The other circuit powers everything that works when the lights are switched off: red from the battery to ignition switch, then orange to rest of the bike.

I don't know what your problem is.
I think I would disconnect everything in the headlight bucket.
Then connect one thing at a time & check what works after each connection made.
Would start with the multi-pin connector for the ignition switch.

[Alan H]

I put comments in the wiring woes thread viewtopic.php?f=2&t=11302" onclick="window.open(this.href);return false;
Did you check that?
The orange is a switched live and it should be full battery voltage when the ignition is on.

[Coyote]

WHY DO I HAVE THIS ORANGE WIRE FREE?????????????????????/ WHERE THE HECK DOES IT GO?????????????

[Suzukidave]

[bill in okc]

Or this one:

It looks like ?three? orange wires that are in the headlight bucket - Two come from the ignition switch, another from the instrument panel. I see one has a note that says 'green color tube' - and I can see what looks like a green tube in your pic - does anything connect to that?

[markush]

Hi!

WHY DO I HAVE THIS ORANGE WIRE FREE?????????????????????/ WHERE THE HECK DOES IT GO?????????????

Because it is not connected to anything. Nobody can follow the wire on your pic.
Why the hell don't you finally pull the wiring out of the bucket and trace the lines up to the switches a.s.o.
Normally there is only one orange wire with single female connector, shown in the wiring diagram (with "green color tube", that could be lost). You have to find the orange wire with male connector, coming from the left hand lighting switch, and put them together. The headlights and taillights otherwise shouldn't work.

[Coyote]

Orange wires with the green sleeves are connected already.

[Suzukidave]

Did you get a chance to follow back where those wires go ?

[Spamy]

I think I had almost the same thing happen. For me it ended up being two almost identical single wires that are behind the wiring panel under the seat. I cant remember exactly but I thought I mixed up one of the gear indicator wires with a signal wire or something like that. It was 2 wires that went up the left side of the frame and terminated individually as single wires (not in a loom) between the battery and the electrical panel.

Ill see if I can find more info.

[Spamy]

I thought it had to do with either the black wire in the pic or the others on the top right. Sorry its not more specific, it was many months ago.

[Spamy]

Perhaps it has to do with the black wires from the alternator, the right rear signal and the gear indicator. Double check those.

[Coyote]

Spammy, mine is laid out a little differently I don't have any wires between the starter solenoid and the V regulator. I have also added a modern blade type fuse. if you follow the red with the jacket, it comes down and loops into the yellow that has the fuse. The yellow doubles back an plugs in where the red splits. All connectors are soldered and protected with heat shrink tubing. Everything is plugged in correctly. The orange and white from the flasher, the yellow from the starter solenoid and the blue neutral wire.
All lights on the bike work. The only one that does not work is the panel turn signal light. It works on the left set of turn signals but does not work on the right set of turn signals. The turn signals themselves are working properly The gauge cluster flash indicator works left but not right. The horn does not work. Tests show it's not getting any power to it.
Working are the tail light, the brake light from lever and foot The gauge lights, the gear indicator and the headlight hi and lo and its indicator light.

[Suzukidave]

Diagram shows horn green & orange and the turn indicator light green (R) and black (L) .... shows when connected up the horn button sends green to ground completing the circuit .