[sharing_s_caring]

2006 Burgman 400 has developed a start problem.
Replaced 6-10 amp fuses and 2-15 amp fuses [ouch nothing wrong with them, oh well now I have spares, a tester and a puller], battery fully charged. Kill switch off, kick stand up, key in correct position, lights work, back break lights work too]

Set up, Bike's on center stand: Turned on ignition switch, F1 error [not flashing], kick stand up, lights work, battery fully charged, left rear brake lever engaged--no sound, cranking, or starting.

Same as above but engaged right front brake lever and bike started.
Can hear fuel engaged sound when cranking.

Think solution from somewhere on this forum was left front brake switch? Said parts ran under $200. Need to know so I can order part(s).

Just paid $400+ and change for front bearings, parking cable installation and brake fluid change on both brake lines. Trip down mountain with big jumping and racket when applying front right brake lever. Emergency visit to closest dealer 3 hours out from home location. Trying to keep the new repair down low haven't paid for the last fix yet.

 

[Buffalo]

Sounds like the left hand brake switch has gone out. You can confirm it by pulling the left brake lever and looking to see if the brake lights come on. If they don't the switch is bad.

Part number for the switch is 57460-17C11. They run about $25. Here is a link to a fiche with the part on it. It is item 5. http://www.partshark.com/fiche_sect...gory=Scooters&make=SUZUKI&year=2003&fveh=7244

As you can see from the fiche it is only held on by a single screw. Takes about 5 minutes to change.

 

[Scootereno]

I would try cleaning the brake switch with contact cleaner.
Sounds like someone got brake fluid in the switch contacts.

 

[Mel46]

Yours started when you held in the RIGHT hand brake, but not the LEFT?? Interesting. Yep, like Buffalo said, sounds like the left hand brake switch is bad.

 

[rut3556]

Make sure your "kill" switch wasn't inadvertently shut off by mistake.

 

[sharing_s_caring]

Cleaned left brake switch contact parts, bike will start one or two times and then nothing--no brake lights using left brake. Bike Still starts when using right brake lever.

 

[etcallhome]

Yep, still sounds like the left hand brake switch is BAD..

 

[sharing_s_caring]

Found a forum blog about recalls on 2012 model and owner had both left and right brake switches replaced. Will call tomorrow and see if I can get them. Aside from the issue of no brake lights in traffic [don't want to be a hood ornament, don't ch' know] the bike would not pass next vehicle safety inspection. And is there a light fuse near the rear of the bike? Would this left brake start problem affect motor until parts are delivered and replaced?

 

[Buffalo]

It will not affect the motor. As you mentioned, as long as the right one works you can start the bike. You just don't have a brake light when you pull the left lever but since the right one works your brake light will come one when you pull that lever.

There is no fuse for the lights near the back of the bike.

 

[Mel46]

I always use both brakes at the same time. Assuming that you do too, you should be OK until the parts arrive. Just be aware of that limit.

 

[sharing_s_caring]

Thanks, everyone. Replaced the left hand brake switch and the problem is fixed.
Finally, got the right hand brake switch weeks later. Dealer had to reorder due to non-delivery with left hand brake switch from Suzuki-paid for both before ordering. : (

 

[oldkid]

I know how stupid this sounds, but it did happen to me once on my 150cc scooter. The brake handle was adjusted too far out where the brake had almost no free play and I had to squese hard to get to the switch to start the bike. After adjusting the free play the brake lights and start circuit were fine.

 

[SkyJockey]

Try removing the relay next to the fuse box on Left side between the headlights and the windshield. Clean the contacts with contact cleaner and re- install. Should fire right up.

 

[danj]

Hello Everyone,

I am new on here and just picked up a 2003 Burgman 400 that has been sitting for 6 years or so. This thread looks like it is similar to my question, so I hope it is alright to post this here. I put in a new battery, turned the key on (can hear what I am guessing is fuel pump priming), and press the start button but no cranking/ no sounds. Now, the kick stand is up, kill switch off, and I am pulling both hand brakes. There is no additional brake light when I pull either brake handle, just the running light is on. Also, the "brake lock" emergency brake handle is stuck about half way in - i am guessing the cable is rusted but the bike rolls easy so I probably won't fix it immediatly unless it has something to do with the no-start.

Thank you!

Dan (Salt Lake City)

 

[zrx212]

There is no additional brake light when I pull either brake handle

That's an issue/problem right there, normally either LH or RH brake lever switch supply 12volt + power directly to both the brake lights and the "Safety Relay", wich connects the starter buttom to starter relay, allows bike to crank. You could have 2 bad brake switches (bad/dirty internal contacts) or no power at switches from fuse box, you can disconnect wires at brake switches, check for 12v on one of the wires(switch on) , if no power, check dirty/poor wiring connectors, dirty or blown fuse, if you get 12v, install a jumper at either switch and try to crank.

" Make sure you apply brakes and/or do this on centerstand, for safety".

The fact that you hear the fuel pump priming, means both your sidestand and kill switch are operating normally.
General notes/PSA, fuses is the first thing to check, not always the issue, usually the result off shorts, broken wires, dirty connectors, bad grounds and/or fuse contacts, etc. " Never jump start or connect scooter/motorcycle battery to a running car/vehicle, you could cause $$$ damage "

IAC, this diagram may help.

 

[danj]

That's an issue/problem right there, normally either LH or RH brake lever switch supply 12volt + power directly to both the brake lights and the "Safety Relay", wich connects the starter buttom to starter relay, allows bike to crank. You could have 2 bad brake switches (bad/dirty internal contacts) or no power at switches from fuse box, you can disconnect wires at brake switches, check for 12v on one of the wires(switch on) , if no power, check dirty/poor wiring connectors, dirty or blown fuse, if you get 12v, install a jumper at either switch and try to crank.

" Make sure you apply brakes and/or do this on centerstand, for safety".

The fact that you hear the fuel pump priming, means both your sidestand and kill switch are operating normally.
General notes/PSA, fuses is the first thing to check, not always the issue, usually the result off shorts, broken wires, dirty connectors, bad grounds and/or fuse contacts, etc. " Never jump start or connect scooter/motorcycle battery to a running car/vehicle, you could cause $$$ damage "

IAC, this diagram may help.

Thank you, zrx212 - that is very helpful!

It sounds like you are pointing me in the right direction with the lever switch contacts. It looks like the bike has been stored in the weather and even the storage compartment buttons are showing wear to the point they get stuck in the open position and have to be wiggled to go be able to hook closed again.

I will update after using a light tester and jumper wire.

 

[danj]

Thank you, zrx212 - that is very helpful!

It sounds like you are pointing me in the right direction with the lever switch contacts. It looks like the bike has been stored in the weather and even the storage compartment buttons are showing wear to the point they get stuck in the open position and have to be wiggled to go be able to hook closed again.

I will update after using a light tester and jumper wire.

I ended up unplugging the two wires connected to the left brake switch and used a paperclip as a jumper to connect the two and the scooter started right up. It looks like I will be replacing both brake lever switches, thank you! (it started raining when I snapped the photo)