Ignition switch doesn't turn off...

[Steveb64]

...on my wifes Bandit 1200S! It WAS working, but now... It locks and unlocks the steering Ok, goes 'click click' and rotates through the appropriate positions - but it won't turn off! Had to disconnect the battery in the finish.

I know it's not a GS - but it's got a GS (GSF1200) in it's model...

I suspect a new switch is going to be required...

Bugger.

Anyone else heard of this occurring?

[duaneage]

Before I spent money on a new switch I would have a look to see what broke and try to fix it.

[torque87]

do you mean sticking like the starter keeps cranking even when the engine is running or what? If that were the case then I would think the starter solenoid is sticking. A similar problem occured on a friend of mine's pickup truck. I appologize if that's not the actual problem, just throwing it out there :P

[Steve]

do you mean sticking like the starter keeps cranking even when the engine is running or what?

No, it does not sound like a starter button/solenoid issue, it sounds like there is something in the key switch that is not turning or there is some crud in there that is shorting across the contacts, keeping current flowing when the KEY is off.

.

[Steveb64]

No, it does not sound like a starter button/solenoid issue, it sounds like there is something in the key switch that is not turning or there is some crud in there that is shorting across the contacts, keeping current flowing when the KEY is off.

.

Yep - or there's a short in the wiring. I've found a spot where the harness from the switch has been pinched badly, so I'll pull the whole switch off, and see how much of it I can get apart. Got a silly (~NZ$500 !!) price from Suzuki for a new switch, so I may as well try and fix it first.

Starter motor doesn't run unless I hit the start button - but the ignition is on all the time. Mutter mutter.... Just when I thought I was getting ahead with it...

Ah well, add it to the list...

[duaneage]

A short in the fuse box will power the bike up all the time too.

[Steveb64]

Fixed!

I pulled the switch off and checked it - OK - then I lifted the tank and pulled the switch harness plug apart - still no change. So switch and harness were OK. In the course of disconnecting various relays and sub-circuits in an effort to find the one that cleared the problem, I spotted a connector that looked like it had gotten a bit warm. Quite hot even... Like it (the plastic outer shell) had welded itself together! I traced it back, and it belongs to the alternator output! It looks like there must have been a bit of corrosion on the plug contacts, which caused some resistance, which caused it to heat up, which melted the thing until the two wires in the plug shorted together, and....

So, after chopping the side off the plug (with heavy side cutters) so I could prise it apart - I crimped on a new spade connector to replace the cooked one, plugged it back together, and hey presto! All working again!

[ansonfehr]

Same story on my 450, haha took my bike through too a motorcycle electrician sorted me out quickly :P