kk600cc
Scooter Rider
2003 BT1100 Bulldog
Posts: 57 
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Post by kk600cc on Nov 5, 2016 16:05:49 GMT
Hi all doing some work on the bike at moment and I thought I would try and sort out why I have to pull clutch in so I can start bike. It as had new neutral switch, new diode in the neutral switch wiring, I have checked all connections and they seem sound also done continuity checks between all connections. On the heater relay the manual as got brn,brn,blk/yel & grn wire going into it mine as got skyblu,blk/yel,red/wht & brn going into it. When I have ignition on and move it out of neutral you can feel the heater relay click as you move it out of neutral and again when put back into neutral, my neutral light on bike works fine and once started bike runs fine. can any tell me what the heater relay does as I thought it would have just been for carb heaters but since there is a sky blu wire and blk/yel wire going into it then it must have something to do with the neutral and clutch switch cut outs. At moment I have the side stand switch bypassed as I am sure the bike thinks it in gear hence the need to pull clutch to start, you can release the clutch once started and it won't cut out and neutral light is on when in neutral and out when in gear and runs well.Photo is below is my set up on 1999 600 any info or thoughts to were the problem might be would be much appreciated thanks kirk. don't know whats happened to photo it keeps loading pic of my old bike instead sorry.  |
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Post by HRHpenfold on Nov 5, 2016 16:59:37 GMT
Hi all doing some work on the bike at moment and I thought I would try and sort out why I have to pull clutch in so I can start bike. It as had new neutral switch, new diode in the neutral switch wiring, I have checked all connections and they seem sound also done continuity checks between all connections. On the heater relay the manual as got brn,brn,blk/yel & grn wire going into it mine as got skyblu,blk/yel,red/wht & brn going into it. When I have ignition on and move it out of neutral you can feel the heater relay click as you move it out of neutral and again when put back into neutral, my neutral light on bike works fine and once started bike runs fine. can any tell me what the heater relay does as I thought it would have just been for carb heaters but since there is a sky blu wire and blk/yel wire going into it then it must have something to do with the neutral and clutch switch cut outs. At moment I have the side stand switch bypassed as I am sure the bike thinks it in gear hence the need to pull clutch to start, you can release the clutch once started and it won't cut out and neutral light is on when in neutral and out when in gear and runs well.Photo is below is my set up on 1999 600 any info or thoughts to were the problem might be would be much appreciated thanks kirk. don't know whats happened to photo it keeps loading pic of my old bike instead sorry. Your trying to fix something that is not broken, all suzukis work that way, triumphs too  If it happens to be a diversion, then it's the diode pack that has failed. |
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kk600cc
Scooter Rider
2003 BT1100 Bulldog
Posts: 57
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Post by kk600cc on Nov 5, 2016 17:09:33 GMT
Hi it is 99 diversion (old bike I had in photo) I have changed the diode for new one but still the same so was wondering if its the main relay now.
thanks kirk.
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Post by HRHpenfold on Nov 5, 2016 18:52:47 GMT
Hi it is 99 diversion (old bike I had in photo) I have changed the diode for new one but still the same so was wondering if its the main relay now. thanks kirk. Have you fitted the diode the correct way around, and did you replace them both? |
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kk600cc
Scooter Rider
2003 BT1100 Bulldog
Posts: 57
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Post by kk600cc on Nov 5, 2016 20:34:55 GMT
The answer might be in have you replaced both. I have only replaced the one in the loom under the tank where the side stand connectors etc are. Do you know where the other one is my haynes manual wire diagram is only showing one diode and looking around must have missed the other one, so if you could point me in the right place to look that would be great.
thanks kirk.
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Post by HRHpenfold on Nov 5, 2016 20:50:40 GMT
The answer might be in have you replaced both. I have only replaced the one in the loom under the tank where the side stand connectors etc are. Do you know where the other one is my haynes manual wire diagram is only showing one diode and looking around must have missed the other one, so if you could point me in the right place to look that would be great. thanks kirk. I have no idea, I only know there are two, because two are shown in the wiring diagram, in the wiring diagram they are both shown in the relay box, but they won't be in the relay box, best just to follow the correct wires from the relay box. From the diagram here, diagram here |
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kk600cc
Scooter Rider
2003 BT1100 Bulldog
Posts: 57
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Post by kk600cc on Nov 6, 2016 17:25:35 GMT
Thanks for diagram, I have got the haynes one's for the 99 diversion. I did today strip all body work off bike as want to work on it over the winter so checked all along the loom and mine only as the 1 diode. The diagram for the main relay is the same as the link to diagram you posted so I think i will pick up a main relay for 97 onwards model over the winter & see if that solves it.
thanks for your help kirk.
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kk600cc
Scooter Rider
2003 BT1100 Bulldog
Posts: 57
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Post by kk600cc on Apr 1, 2017 10:00:33 GMT
If this helps any one in the future I got this sorted finally and it was in the main relay, there are diodes in that sealed relay. The relay is 3EN-81950-00 from the 97 D6 models on but they are shared on a few different models (https://www.bike-parts-yam.com/yamaha-microfiches-affectation-piece.html?text_recherche2=3EN-81950-00) so I got from a 94 900 divvy and all works fine now clutch and side stand starting and cutting bike out when sould.I think when the person that had bike before me some one might have tried to nick it as it had just been fitted with new ignition and neutral switch so in process might have blown the diode.
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Post by GAv on Apr 1, 2017 13:44:20 GMT
Hi all doing some work on the bike at moment and I thought I would try and sort out why I have to pull clutch in so I can start bike. It as had new neutral switch, new diode in the neutral switch wiring, I have checked all connections and they seem sound also done continuity checks between all connections. On the heater relay the manual as got brn,brn,blk/yel & grn wire going into it mine as got skyblu,blk/yel,red/wht & brn going into it. When I have ignition on and move it out of neutral you can feel the heater relay click as you move it out of neutral and again when put back into neutral, my neutral light on bike works fine and once started bike runs fine. can any tell me what the heater relay does as I thought it would have just been for carb heaters but since there is a sky blu wire and blk/yel wire going into it then it must have something to do with the neutral and clutch switch cut outs. At moment I have the side stand switch bypassed as I am sure the bike thinks it in gear hence the need to pull clutch to start, you can release the clutch once started and it won't cut out and neutral light is on when in neutral and out when in gear and runs well.Photo is below is my set up on 1999 600 any info or thoughts to were the problem might be would be much appreciated thanks kirk. don't know whats happened to photo it keeps loading pic of my old bike instead sorry. Your trying to fix something that is not broken, all suzukis work that way, triumphs too If it happens to be a diversion, then it's the diode pack that has failed. Yep his regal highness is correct you have to pull the clutches in on both my Suzuki TLs engined Cagivas, before they will start. |
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kk600cc
Scooter Rider
2003 BT1100 Bulldog
Posts: 57
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Post by kk600cc on Apr 1, 2017 15:20:39 GMT
Hi Gav that photo is of an old bike I had when loading photo of divvy from photobucket at time of first post and couldn't get it to load right one. At the time view was there would not be a diode in the relay as I had already done the one in the loom and couldn't find any more, but after finding out on fzr site the relay does have diode in there and it would fix it. Just not to confuse it for any one I was working on 600 diversion.
kirk.
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Post by bigfootisblurry on Apr 1, 2017 20:14:28 GMT
On a related note, should my D9 start in gear with the clutch in? The Haynes suggests it should but mine only starts in neutral regardless of the clutch.
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kk600cc
Scooter Rider
2003 BT1100 Bulldog
Posts: 57
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Post by kk600cc on Apr 2, 2017 7:46:58 GMT
Yes it should as long as the side stand is up, it was one of the issue's I had.
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Post by bigfootisblurry on Apr 2, 2017 9:26:52 GMT
Yes it should as long as the side stand is up, it was one of the issue's I had. How did you fix it? |
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Post by GAv on Apr 2, 2017 9:51:41 GMT
There may be a connector into the left side of the mount where the switches and mirror fits ?
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kk600cc
Scooter Rider
2003 BT1100 Bulldog
Posts: 57
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Post by kk600cc on Apr 2, 2017 9:53:23 GMT
I first checked the neutral side stand and clutch switches and then the diode in loom under tank all these were fine so only thing left was to change the relay and got a used one put that in and all working as sould now. So for mine the fix was changing the relay.
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Post by GAv on Apr 2, 2017 11:16:35 GMT
Well done glad you got it sorted. I am down a bike again-well two as I sold my Suzi Van Van Chinese knock off(Skyteam VRaptor)a few weeks back.  I just sold one of the Cagivas(I didnt need two & had hoped to get more, on the basis what folk are asking, but are still advertising. got my money back in all respects as I had sold the upswept pipes,(well Ok made a small profit) a guy drove all the way down from Newcastle upon Tyne for those and I put the Art ones on it instead. (So it is one less for some scrote to take walkies) regarding Penfold's remark about all Suzukis are the same, my DoctoR engined Sachs starts on the button-well sometimes-no need to pull in the lever to start it. |
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