1994 Suzuki intruder electrical problems

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1994 Suzuki intruder electrical problems

#1 Unread post by fra88777 » Sat Nov 10, 2007 10:07 pm

I have a 1994 Suzuki intruder 800. I have been having an electrical problem. When I go to start the bike as soon as i hit the starter there is a clicking noise coming from the ignition system area and all power just shuts off completely. I have already replaced the ignition system and am still having the same problem. I can literally shake the bike and the power will switch on.

The guys at the shop said it could be the solenoid which has been on there since i bought it. I ordered a new one and am going to try replacing it and seeing what happens. This bike is my only transportation, which has always been fun but its a real hassle right now.

Does anyone have any input on what they think it could be and if the solenoid could be the problem. Any input would be a help. This problem has been re-accuring and has been very frustrating. Thanks.

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#2 Unread post by fra88777 » Sat Nov 10, 2007 10:12 pm

This sounds a lot like what is going on with my bike ( viewtopic.php?t=22324&highlight=solenoid ). I have taken it to a few different shops and none of them have actually fixed the problem, just made it run.

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#3 Unread post by Johnj » Sun Nov 11, 2007 2:18 am

It sounds like your battery may be bad. Do you have, and can you use a voltmeter?
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#4 Unread post by fra88777 » Sun Nov 11, 2007 2:24 pm

I don't have one no. The battery should be fine though i replaced it not too long ago. My thoughts were that it was something to do with a connection or the solenoid itself. I was told the clicking noise was the breaker getting kicked. Still not sure though ill have to see if replacing the solenoid does anything. I need to check all the connections while i do that too i think. Thank you much for your input. - Forest

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#5 Unread post by fra88777 » Sun Nov 11, 2007 2:31 pm

Does anyone agree with this, its the answer i got from someone at allexperts.com.

Forest,

it sounds like your circuit breaker is faulty.
-A red wire goes to it on one side, that is the
battery power. On it's other side is a red/white
wire which leads back to your fuse panel.

-That circuit breaker is probably what is
making the clicking sound.

-Check around behind the fuse panel
for a little box with a red and red/white
wire coming out. It might have a red reset
button on it.
Reset or replace it and then make sure
your fuses are still okay as well.

-always make sure the battery cables are tight
on these bikes, they tend to loosen and
cause weird problems.
-make sure your battery is charged up
and it may still need the new solenoid
if it kicks the breaker when starting.

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#6 Unread post by coffee_brake » Sun Nov 11, 2007 9:34 pm

My first bike was a '94 Intruder 800 and it had a terrifying glitch that would cut power and kill the bike (on a curve in the dark on a mountain with no shoulder and no streetlights, for a rank scared newbie). It turned out to simply be an electrical connection under the seat. Later on, the connection at the battery was also loose and I didn't understand why the bike was leaving me on the side of the road. This "click and won't start" definately sounds like a connection, since you say the battery is new. You've maintained the water level in the battery cells, right?
Always, start with the simple and free checks. In this case, the connections. Get your manual (I like Clymers), check the connections to the battery, starter, and ignition. Yeah, and circuit breaker. Also, you could put the battery on the charger to see if it simply ran down. Then, move on to considering replacing more parts.

Finally...find another shop and get a second opinion. Throwing the parts cannon at this problem without checking the simple stuff is plain dishonest and ugly. If that is, in fact, the case. Sounds so.
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#7 Unread post by BuzZz » Mon Nov 12, 2007 2:12 pm

Shake the bike and you get power all of a sudden? It almost has to be a bad connection from the sound of it. Check everything, all you just replaced and especially anything you didn't replace. Hopefully it is a bad connection and easy to find. Grounds are especially finicky, they can seem tight but a little corrosion under the connector can raise bloodly hell with continuity and really mess with operation.

It could be a wire that has broken inside the insulation someplace, and they are a blitch to track down. With luck the break will be just past a connector someplace, rather than in the middle of a long run of wire. If you can, test continuity of each wire both as it sits and when you are gently tugging and moving the wire.

If you absolutely can't find a bad wire or connection, then it's time to look at individual components and test each one in the system. Test them, shake them, re-test them, test them hot, cold and any other way you can think of.

Good luck tracking it down, it can be a real PIA sometimes.

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#8 Unread post by fra88777 » Wed Nov 14, 2007 11:04 pm

Thanks so much guys. I will take the advice and report back. I already bought the solenoid so ill just put that on anyways, might as well. I will make SURE to get the shop guys to check all connections before replacing any parts. I think i will go to a different place too i feel like they are being lazy and not wanting to try the simple things and instead wanting to replace expensive parts. Thanks guys, i will report back after i try some things. Peace.

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#9 Unread post by ofblong » Thu Nov 15, 2007 1:32 am

lol I just had a problem this past summer with this. Ended up being the positive terminal wire came loose so it was sometimes making sometimes not. Tightened the bolt down and whala no more problems until last week when I found I have a bad spark plug wire draining my battery down.
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#10 Unread post by coffee_brake » Thu Nov 15, 2007 11:56 am

Good on ya FRA...don't be afraid to get in there and start checking connections yourself. The Intruder is a remarkably durable and simple bike. Oh, do I have stories of what I unintentionally did to that poor machine and it STILL ran great all the time...I bet if you can meet some other riders and find some good folks to run with, bikers tend to help out other bikers.

Ofblong---bad plug wire draining the battery? I have never heard of this. How does something like this happen? Could you tell us more about this?
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#11 Unread post by fra88777 » Thu Nov 15, 2007 4:32 pm

Update on whats going on. Today I went to try to put on the new solenoid i got. I took off the side plates and seat and could not get to the bolts that hold on the solenoid. After trying for a while i gave up frustrated and put the seat and side coverings back on. Before i left i popped the key in and turned it, and walah it came on! I guess while i was moving all the wires around under the seat i reconnected the short. I rode the bike back home and i am going to take it to a smaller more humble shop tommarow and have them check over connections. I think i know more now I'm pretty sure its a short. Hopefully they can track it down. Funny how that worked out huh, haha. Thanks for all the input fellas, and ladies. I will update when i hear back from the shop. Peace and love. -Forest

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#12 Unread post by ofblong » Thu Nov 15, 2007 11:51 pm

coffee_brake wrote:Good on ya FRA...don't be afraid to get in there and start checking connections yourself. The Intruder is a remarkably durable and simple bike. Oh, do I have stories of what I unintentionally did to that poor machine and it STILL ran great all the time...I bet if you can meet some other riders and find some good folks to run with, bikers tend to help out other bikers.

Ofblong---bad plug wire draining the battery? I have never heard of this. How does something like this happen? Could you tell us more about this?
because when you have a shorted plug wire it tends to take ALOT of juice to try and fire that cylinder because of the short. It wont drain the battery right away but can take a few days (in my case 2-3 cause of how often I started and stopped the bike). My bike has 2 wires which makes it difficult. Something like your car that has 6 cylinders isnt gonna matter much battery wise because 5 are still starting not requireing much battery power. with my bike that short was causing my system to not get enough power to be able to charge the battery fully because it was constantly sending EXTRA volatage to that wire because of the short. I am having a hard time explaining what I mean so hopefully I didnt confuse you lol.
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#13 Unread post by crazypj » Sun Nov 18, 2007 3:33 pm

The Intruder has a weird battery placement and most people get it wrong when fitting a new battery (its behind the transmission and has to be fitted from underneath) The solenoid clicking is due to battery problem. You have low volts, hitting starter button energises solenoid coil which activates contacts o starter moor causing around an 80~90 amp draw. This lowers voltage until solenoid cant keep contactors in place so they drop and the cycle repeats as long as your holding starter buton and you get the brrrrtt noise.
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#14 Unread post by fra88777 » Sun Nov 18, 2007 6:13 pm

I kind of understand what you said. But why do you think that messing around with the wires under the seat could of fixed the problem. That is what made me think its a short. Because i didnt touch the battery or the battery connections, that doesnt match up in my mind at least.

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#15 Unread post by crazypj » Sun Nov 18, 2007 7:29 pm

If it was a short you would either blow main fuse or set fire to wiring. More likely you have a loose connector. Have you had any work done on bike which needed tank/seat removal? maybe just pulled a connector apart and its a bad contac.
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#16 Unread post by crazypj » Sun Nov 18, 2007 7:30 pm

If it was a short you would either blow main fuse or set fire to wiring. More likely you have a loose connector. Have you had any work done on bike which needed tank/seat removal? maybe just pulled a connector apart and its a bad contact.
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#17 Unread post by fra88777 » Sun Nov 18, 2007 11:11 pm

The only work that has been done under the seat im pretty sure was just me tinkering around. But a loose contact sounds about right, seeing as after i was done messing around it started right up. Its in the shop now and i explained as well as i could to the mechanic what happened. I'm just hoping he can get it to malfuntion again so he can use the voltage meter on it to track down the problem. I think he should be able to by doing the same thing i did though.

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