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Discussion Starter #1
I have a 400 that was spose to be recalled for bad switich, it has now quit working and the dealer just said he's sorry...............

Is it possible to hot wire it without taking the body off?
Thanks for information, ideas, help, ..
Johnperson
 

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How old was the bike?
 

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Your would have to pull some body work off to even attempt to hot wire it.
 

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Well, it is 9 years old so warranty/consumer law is not going to come into play.

However you could ask the dealer to establish if the recall notification applies in this case and if that re-work was ever done.

Linky

Linky 2
 

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Discussion Starter #6
when I turn the key to run the bike is dead, When I turn the key to parkimg light, the turn signal and em flasher power up? I read it could be a ralay? I want to hot wire it. I have a red, a orange then two tan with a pink stripe. I figure the tail is the orange, the red is hot and the two other wires go to the relays to power up the bike. Any ideas, I don't want to do more damage. The bike has over 40k. THANKS
 

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Same thing happened to my '05 in 2011 (had about 18000 miles at the time). Bummer.
 

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when I turn the key to run the bike is dead, When I turn the key to parkimg light, the turn signal and em flasher power up? I read it could be a ralay? I want to hot wire it. I have a red, a orange then two tan with a pink stripe. I figure the tail is the orange, the red is hot and the two other wires go to the relays to power up the bike. Any ideas, I don't want to do more damage. The bike has over 40k. THANKS
When I look at the wiring diagram in my service manual for the 05 400. your wire colors don't match what it says. The manual shows six wires going to the ignition switch except for the UK. EU and Israel models which have 4 wires. In either case no tan with pink stripe wires are shown.

The UK/EU/Israel model has a red, orange, orange with green stripe and a black with red stripe wires. According to the manual, when you have the key in the park position you should have connection between the read and black with red stripe wires. When it is in the run position you should have connection between the red and orange wires and between the orange with green stripe and black with red stripe wires.

The other models have red, orange, orange with yellow stripe, black with white stripe, orange with green stripe and a black with red stripe wires. When you have the key in the park position you should have connection between the read and black with red stripe wires. When it is in the run position you should have connection between the red and orange wires, between the orange with yellow stripe and black with white stripe wires and between the orange with green stripe and black with red stripe wires.
 

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I also looked at the wiring diagram for the 04 model and it seems to show the same thing as the 05 model.
 

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One other caution with hot wiring. Even if you do get the wires hooked up right it may not start. In another thread someone posted that the ignition switch has a resistance built into it that the ECM can detect. If you hot wire it the ECM will not see that resistance and it will not let the bike start. I can't verify that as I've never measured the resistance through the switch or tried to hot wire one but thought I would pass it on.
 

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ignition switch, KEY i,v been having problems with mines as well, Wondering is there a way to service it, but it surrounded aluminum Part,
 

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ignition switch, KEY i,v been having problems with mines as well, Wondering is there a way to service it, but it surrounded aluminum Part,
Yes and No.

If you pull the whole ignition switch assembly out and look at the end of it opposite the key end you will see a couple of security style screws. Take those screws out and you can pull the electrical part of the switch out of the housing. This would be the part the wires plug into. That does not get you much though because Suzuki does not sell the electrical part of the switch assembly as a separate item. All you can buy is the whole switch assembly.

You can pry the back of the electrical part of the switch off and possibly repair what is wrong inside it. But you are on your own in making those repairs as no parts are available. You will have to rig what ever you need.
 

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Just happened. I have less than 5000 miles on a 2005 burgman 400. I turned the key and everything went dead. no lights, no brake lights, no dash lights. the only light that comes on is the trunk light. Anybody else have this problem, and know how to fix it?

Is the bike ridden regularly (5K in 8 years is not many miles)?
When was the last time you turned the key and things worked?
 

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thanks Buffalo,

Chatman128, Sounds like you have something similar to what's happening to me, I turn the key to the Right but nothing happens until i Tap the Key a little then it comes on, I'm gonna try spraying WD-40 in the Key port first and see what happens i real sure, that the Copper Contacts inside may have Build up Carbon on them, if all els fails then i will Remove the Device and do what Buffalo said open it...

Elliott,
 

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I would have the battery load tested, my 650 did the same thing. It was the battery, it had only about 20% capacity amps, voltage read good at 12.8 after full night on charger.
Jim
 

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Chatman128, Sounds like you have something similar to what's happening to me, I turn the key to the Right but nothing happens until i Tap the Key a little then it comes on, I'm gonna try spraying WD-40 in the Key port first and see what happens i real sure, that the Copper Contacts inside may have Build up Carbon on them, if all els fails then i will Remove the Device and do what Buffalo said open it...

Elliott,
A friends 650 did the same thing and it works fine after spraying it down good with contact cleaner, build up of gunk and corrosion.
 

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It worked fine in the morning. in the aftrnoon it just went blank. I bought this scooter used in 2010 with only 200 miles on it. So I did do the orginal break-in miles and maintainence.
 

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thanks Buffalo,

Chatman128, Sounds like you have something similar to what's happening to me, I turn the key to the Right but nothing happens until i Tap the Key a little then it comes on, I'm gonna try spraying WD-40 in the Key port first and see what happens i real sure, that the Copper Contacts inside may have Build up Carbon on them, if all els fails then i will Remove the Device and do what Buffalo said open it...

Elliott,
Spraying contact cleaner in the key side may clean up the tumblers that the key works but it will do nothing for the electrical contacts. The electrical contacts are a good 8 to 10 inches down the switch on the other end inside a separate plastic housing. The cleaner will never reach them. Refer to this thread to see what I am talking about. http://burgmanusa.com/forums/12-general-discussion/50790-ignition-switch-if-only.html It is a switch out of a 650 but the 400 is made the same.
 
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