1991 Suzuki intruder Wiring Madness

[Johnny77]

Hi all losing my mind here. Grabbed this 1991 suzuki intruder 750 and it won't turn over. Tore the bike apart found this harness piece not attached to anything and the end looks burned, 2 of the posts have keyed power. Turn the key on, no fuel pump no no starter no power to starter solenoid. This plug has to be the answer, but I've had 7 people look at it now and there's nowhere for it to plug into. Help me confirm I've lost my mind. Cheers and beers.



https://photos.app.goo.gl/Es3ST3T2uVDPXYPY9

[navigator]

Service manual with schematics here:
http://www.intruders-alert.com/viewtopi ... =13&t=3346

Check the color codes for the wiring.
It may plug into the kickstand relay attached to the underside of the seat....or maybe that relay is missing. ;IDunno:

You will not have power to the starter or solenoid until you are in neutral, and the clucth lever is pulled in.
You will not have power to the fuel pump until the engine is cranking.

[Johnny77]

The clutch is pulled and the kickstand up for all of this lol. It's so strange there's literally nowhere for this to plug into crazy. If there's a missing recepticle for this, then how did it run a week ago. Super mystery.

[navigator]

What color are the wires?
Have you had the tank off?

[Johnny77]

Yes tank off side covers off air box out all trying to find where this plugs in. Let me see if I can post a picture.... [img] https://imgshare.io/image/48LHX
https://imgshare.io/image/48Qzp
https://imgshare.io/image/48KIu https://imgshare.io/image/48FFf
https://imgshare.io/image/48DYd
https://imgshare.io/image/481j7
https://imgshare.io/image/48gaq
https://imgshare.io/image/484Kg
[/img]

[navigator]

If the wires are (2) O/W, B/R, G...Then it plugs into the relay attached to the underside of your seat.
Relay is about 1" square.

Marked:
OMRON
G8MS-S25
12V
2085D6

[Johnny77]

OK THANKS that the first bit of headway..... Yes those are the correct wire colors too. Now my issue is that there is no relay of any kind under the seat or anywhere else that this plugs into. Are you saying that this relay is literally attached to the seat and mine is just outright fell off or lost somehow it's the only thing I can think of lol lol!? Any chance you have a picture or a link to a picture of the relay so I know what I'm looking for? Thanks again and cheers!!!

[navigator]

On the newer bikes it was hooked to the seat, yours may not have been.
If it ran last week, you unplugged it in your disassembly, maybe mislaid it??

https://www.ebay.com/itm/NEW-OEM-SUZUKI ... SwnDpaKzp4

[navigator]

Check for the proper part number, The picture from ebay is just a reference.

[Johnny77]

Well thanks everyone!!!! It sure looks like this is the issue it's exactly what this wire would plug into. My bike outright doeent has this part no wonder I couldn't find it hahaha! I have no idea how it went missing but it did. So they're calling it a sidestand relay. I will try to get one and plug it in and see what happens!!!! Thanks again!!!!

[navigator]

[emoji41]

[Johnny77]

OK it was located under the passenger seat!!! Will hook it up. Tomorrow and see!!!

[navigator]

Your no crank issue still may be non related.
Check your kill switch, bypass your clutch switch.

[Johnny77]

OK here is where I'm at. Found the relay and plugged it in. Turned the key full lights everything. Starter button still does not work. Clutch in and kickstand up. Like wtf. Spanned the starter solenoid with a screwdriver and the engine turns. What now.

[navigator]

OK here is where I'm at. Found the relay and plugged it in. Turned the key full lights everything. Starter button still does not work. Clutch in and kickstand up. Like wtf. Spanned the starter solenoid with a screwdriver and the engine turns. What now.

I answered that here:

Your no crank issue still may be non related.
Check your kill switch, bypass your clutch switch.

check your kill switch, then bypass the clutch switch by unplugging the two wires and jumper them together with a paperclip, wire, fuse, etc.

[navigator]

Did that work??
It could also be the IGN fuse.