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My 2008 Suzuki GZ250 has an intermittent issue with the start function (not the starter motor). It seems to happen when the bike has already been running but has also happened when dead cold.

Most of the time it starts just fine, everything works. But occasionally it is as if a wire became disconnected or a relay just fails to respond. I get no starter response even though all the lights are on. If I happen to be riding when this happens and have forward movement, I can simply let out the clutch while in gear to start the bike that way.

It seems like a connection issue or a relay issue but I am more suspicious of the relay, especially after looking at the switches and what of the wires that I could. Is this a common issue to my bike? The relay costs $110 to replace which is a burden since I am only working part time currently.

Any suggestions or thoughts? I would like to positively identify the issue before committing dollars to a fix. I have a simple continuity tester and a DVM but the weather has been bad the last few days and this is not a garage kept bike, I have to work in the street when weather permits.

Hey bud. How many miles are on it?

It sounds to me like the starter brushes are worn out.

If you're looking at the bike from the right hand side (as you're sitting on it), there's a cap that says Suzuki on the side of the engine. Just to the right of that, under the exhaust pipe, is a little cover, and it has your starter motor in it. If you pull that out, you can then disassemble it. I will warn you that reassembling it usually takes approximately 2 more hands than you have at any given time, but it can be done. Patience and dexterity are what is required for it.

Also be very very careful taking it apart, as the brushes are spring loaded, and will disappear into a corner never to be seen again lol. Take it apart slowly, and when you see pieces pressing against the outer case start to come into view, hold them down. There are 2 of them, so one you'll see, the other is directly 180 degrees from it on the other side.

This sounds a whole lot more complicated than it is, you'll see once you pull it out.

If either of those brushes (made of carbon) are cracked, or worn away, there's your problem. Pretty easy/cheap to replace, and you're not out 110 bucks for the starter relay.

I really don't think it's your relay, as those usually go out completely.

Your other option it could be is an inconsistent connection at the starter switch. Again easy to check. Follow the wires coming out of the right handlebar switch gear until you get to a plug and unplug them. You'll see a Yellow wire with a green stripe on it, and a Orange wire with a white stripe on it. Put your continuity tester on those two. It shouldn't have any continuity until you press the starter button. Then it should have full continuity once you press the button. It might have .1 or .2 Ohms of resistance, but it should be very close to none. If that's your problem, simply disassemble the switch housing, and use some electrical cleaner (sold in an aerosol can at any auto parts store) to clean it up. You can also use a pencil eraser to clean it up.

I have about 6k miles on it.

Wrider wrote: I really don't think it's your relay, as those usually go out completely.

Taking your word for their general behavior, that is an excellent point. I will do as you suggest and check those starter bushings ASAP. BTW, is it at all possible to tap or turn the rotor so that the starter motor turns a little to make a circuit without taking it apart? IE if I get stuck on the road and need an emergency solution (before getting the brushes changed).

Thanks!

Normally yes, but that one is encased in the engine itself, so not on that one.

If you do get stuck out somewhere, you can use the same principle of bump starting the bike as when you have momentum.

Key to on position, make sure it's ready to start, then put it into 2nd gear, clutch lever pulled in. Run the bike as fast as you can, then when you're as fast as you can get it, jump on the seat and let the clutch out. That will bump start it just like if you're already moving and it dies. It may take a few tries, but it is possible. I had to bump start an FZ1 the other day like that... Not fun!

Drat, okay. Thanks again Ryan!

Not a problem! Hopefully its simply the brushes!