1983 GS100esd starter relay wire

[Guest]

OK Well The good news is the bike ran like a bat out of hell after we by passed the starter relay and took it down the road. The bad news is that I must have wired the starter incorrectly after replacing my R/R and cleaning up the wiring. As far as I can tell it looks like I followed the wiring diagrams. After finally getting it all put back together based on the great help I got here, I started the bike. The starter worked and it ran ok until it warmed up a bit and then ran great. When trying to restart it after turning up the idle a bit, the wire attached to the starter relay started to smoke and burn when the starter button was pushed.

I bypassed the relay and the bike started right up with plenty of juice from the battery. While trying to use the starter switch the battery seemed weak and the battery light was on. See the attached picture. Again the bike ran great after started by bypassingIMG_1808.jpg the relay. Can anyone give me an idea where I went wrong here. Any help would be much appreciated!

[posplayr]

Sorry; good luck.

[Steve]

Can't tell what wire is burnt in that picture, but it's not the "starter relay" (solenoid) wire.

Just for the record, replacing the R/R would have nothing to do with the (non-)operation of the starter.

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[loud et]

I think a visit to the wiring diagram in the Suzuki manual for your bike is in order.
The minimal connections in the system pertaining to the battery, starter,solenoid, and chassis ground are very simple upon looking in the manual for my other GS's.
I don't want to tell you wrong on your 83 but I'm guessing the system is as simple as on mine.
Note, there is a very simple solenoid available at Lowes home improvement in the tractor section. 12$ if you need it. Many here have used it. Not saying that's your problem but the part is easily available if needed.

[Piney1100]

It is one of two black and white wires that comes out of the wiring harness and connects to the starter relay switch on the negative terminal.

[Piney1100]

Thanks loud et. I will check the manual and trace the wire back to its origin. Can't hurt to try a new solenoid. Thanks.

[Piney1100]

Would a bad solenoid cause such resistance and burn the wire?

[posplayr]

It is one of two black and white wires that comes out of the wiring harness and connects to the starter relay switch on the negative terminal.

you have managed to create a direct short.

[Steve]

It is one of two black and white wires that comes out of the wiring harness and connects to the starter relay switch on the negative terminal.

There is no "negative terminal" on a stock Suzuki solenoid.

There is a large wire that comes from the battery.
There is another large wire that goes to the starter.
There is a smaller (usually yellow, with green stripe) wire that comes from the starter button.

The solenoid is grounded to its mounting plate, which, unfortunately, is rubber-mounted, so it needs to have its own grounding wire.

.

[Piney1100]

you have managed to create a direct short.

Im sure you are right. I'll have to refer back to the diagrams but Im certain i wired it correctly but for the solenoid. I'll also have to trace and replace the burned wire.

[Steve]

Can you see enough of the wire to tell what color it used to be?

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[glib]

Maybe you meant to connect it (black/white ground wire) to the solenoid mount rather than the post. I accidentally did that when trying to wire up the single point ground. Burned the insulation off that wire in a second.

[bobgroger]

Black with white stripe is always ground on a Suzuki. Starter Solenoid trigger is Yellow\green stripe