No Electrical Power?? Green connector issue!

[ARoden]

Thanks JeffSV. I brought a copy of your photos to the dealer. I had the same problem. Have to go in tomorrow to give them my warranty info and talk them into replacing whole electrical system...

[The real Viking]

Just recieved my bike back from the workshop.

The problem was actually the battery terminals. Quite puzzeling, as the alarm would work (incl. indicators) while the rest of the bike was dead...

The mechanic said that it was not unimportant to keep the power cables directly on the terminals - and keep them clean. In my case, the PCIII and alarm wires were connected under the power cable, hence creating the risk of oxidating of the terminal.

Cost me a bit of time and money, so you might wanna be a little more thorough cleaning the terminals than I was...

[dadmun]

Originally Posted by The real Viking

The mechanic said that it was not unimportant to keep the power cables directly on the terminals - and keep them clean. In my case, the PCIII and alarm wires were connected under the power cable, hence creating the risk of oxidating of the terminal.

Ah yes, that is a good point. I have my alarm and PC connections on top of the bike's connectors. Also, my alarm powers the signals through the alarm itself, so that's probably why your alarm did the same, but the bike couldn't do it.

Well, I'm glad you got it sorted.

[ARoden]

BTW mine is a Copper 2003S leftover. Bought it this spring and had 4000 miles on it when issue started...

[NetBikeGuy]

Glad I found this thread! When I get home tonight I will be lifting the tank to check the ignition harness/connector. About a month ago I ended up caught in a bad rainstorm. Besides getting soaked, the bike kept cutting out as I was riding. Exactly the same effect as if I had turned the key off and back on. Duration of each cut-out was .5 seconds to about 3 seconds. All indicators off, headlamp off, no ignition. Then it would jump back to life, cycle the idiot lights and be back on the power as if nothing happened. The next 10 times I rode (all on sunny days) it was perfectly fine. I thought the extreme rain was the problem. No such luck! Last week the exact same problem happened again, dry and 80F outside. This time worse than before. First it would not turn on at all after stopping for gas. I pulled on wires and turned the key a bunch of times and it came on. I headed for home right away. I was 25 minutes out and it must have shut down 15-20 times on the way. I was on a nice straight highway - thankfully no turns or curves to dump it on. Made it home and it's been sitting as I thought of taking it to the dealer. At least I have an idea what to look for now. SV1000 forum comes to the rescue again! BTW, it's is a silver '03 S with 3,900 miles. First problem I've had, out of warranty of course. Thanks again for the info (and pics of melted connectors!)

[paddy2bsure]

Mine has been very good again for the last few months, but it has let me down only once, heavy rain, stopped for fuel, etc etc. It's always comforting to know there's more of us out there. BTW... 03, 3900 miles? Better not mention that I've done 8000+ miles since I picked mine up on April 18th (2005)!!! Get out there!

[2WIN]

I had mine apart last weekend for the TPS and TB sync and put RTV on top of the plug to keep water from getting down into the plug. Hopefully that will keep the issue from happening. Also the fact that it never see rain or a hose will help!


Cheers

[Macabre]

10,900 miles, mine just started cutting out while riding. Now taken apart in the garage, found the green connector looking just like the one in the pic on page1. Think I'll try and find some generic connector, it's just four poles.

[Tundra Tom]

Tried to start mine last night after dinner at some friends. Dead....nothing, no dash, lights, anything. I checked the main fuse but I knew (thanks to this site) what it was.
After taking the harness apart I can tell it is NOT corrosion from moisture, nor is the plug working itself loose. Hell it took longer to disconnect it than to fix it.
It's a design flaw pure and simple. The small blades of the connector cannot handle the current the larger diameter wires are running through it. The blades heat up, melt the plastic around them till the blades are no longer touching or arcing. Thank God I wasn't hauling ass through a sweeper at mach 10
Bringing it to a dealer is fine as long as they don't use the same shitty connector. I just cut the wire from both ends of the plugs and used larger, insulated bullet connectors. Soldering to one of the leads with 10 gage wire to have some length to work with. It's quite easy after you pull the male end of the plug back under the cross brace. While I was at it I taped up the exposed wires, including the wires running to the Yellow connector next to the green one. Photo shows green harness taped-Yellow harness in stock form. Typical poor Suzuki fit and finish.
I am for sure reporting this to:
http://www-odi.nhtsa.dot.gov/ivoq/
as I believe this is an on going and a KNOWN hazzard to the owner.
So much for "being lucky"!

[2WIN]

Damn... Now I have to take mine apart again.



Maybe that will happen on Friday when I take it off to get ready for the ride-out.

Damn... Damn Damn

Cheers

[JeffSV]

Originally Posted by Tundra Tom

I am for sure reporting this to:
http://www-odi.nhtsa.dot.gov/ivoq/
as I believe this is an on going and a KNOWN hazzard to the owner.
So much for "being lucky"!

Hazard for sure...mines reported on there....Suzuki should be forced to recall if there is enough know complaints. If you havn't reported your fried plugs yet DO IT http://www-odi.nhtsa.dot.gov/ivoq/

[Tundra Tom]

Going through the process of reporting on the .gov web site I found they did not have Suzuki listed in the drop downs for motorcycles. ??? I just entered the model / brand in the complaint text section. I would have liked to include some digital pictures too but there's no download section for them.

I truely think everyone should look at this connector on their SV. You cannot tell if it's damaged with out disconnecting it. Mine was melted most of the way back in the male plug. The least that will happen is it'll leave ya stranded somewhere, or worse it could start an electrical fire under your gas tank, or worse yet cut out while your deep in a corner!

Works fine now, will give it a big test this weekend.

[2WIN]

Originally Posted by Tundra Tom

Going through the process of reporting on the .gov web site I found they did not have Suzuki listed in the drop downs for motorcycles. ??? I just entered the model / brand in the complaint text section. I would have liked to include some digital pictures too but there's no download section for them.

I truely think everyone should look at this connector on their SV. You cannot tell if it's damaged with out disconnecting it. Mine was melted most of the way back in the male plug. The least that will happen is it'll leave ya stranded somewhere, or worse it could start an electrical fire under your gas tank, or worse yet cut out while your deep in a corner!

Works fine now, will give it a big test this weekend.

What color wires are they? I am going to do it today or tomorrow so that I don't have an issue with it at all.

Cheers

[Tundra Tom]

Originally Posted by 2WIN

What color wires are they? I am going to do it today or tomorrow so that I don't have an issue with it at all.

Cheers

The wires are Black with a Red stripe on one end and Orange (?) on the other.
When you lift the tank the connectors are on the inside of the frame behind the steering head. The three connectors are mounted to a plate against the frame with the green (bad) connector on the left end, the yellow one in the center, and a black one on the right. The Green connector slides off the mounting plate upward. You then unplug it and pull one end down under the cross brace to work on it. I unscrewed the mounting plate from the frame but I'm not sure you need to do that to access the plug.

[2WIN]

OK.

I made the change to mine today. I cut both large wires though and used friction lock connectors to reattach them. I saw both very large wire. Red to orange and black w/red stripe to orange wires and decided to fix them both.

My plug with around 4400 miles on it, was like new. No melting had started.

I used plenty of dielectric grease and black tape before reinstalling both.

Cheers