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Suzuki 800 Intruder Club & Forum

A UK Site Dedicated To The Suzuki C800, VL800, VX800, M800, VZ800, VS800, C50, M50 Model Intruder / Boulevard / Marauder
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 1998 VS800 65,000mi Clutch Start

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PostSubject: 1998 VS800 65,000mi Clutch Start   Tue Oct 24, 2017 4:30 am

Bike let me sit second time, (first time spider spun a web between the fuel pump reverse contacts overnight while tent camping) clutch switch start interlock. At first fucking with the clutch switch would make it start. Then only by jerking front wheel left. Then nothing & I traced it to y/g wire from clutch switch to starter relay. When I moved the wire harness around at fork it would make contact. Disconnected the two handlebar wire harness & took the handlebar off. The left side harness cover is split in half, the right only half split. Pulled the right side cover off. The two green w yellow tracer wires from the clutch switch are solid. Can’t pull them apart or get them to move the meter from infinity. Checked all wires going to handlebars and all seem fine. Now I’m back to is the clutch switch shot. 
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PostSubject: Short jumper under seat.   Wed Oct 25, 2017 1:36 am

Can't believe it, the problem was the short yellow/green double female that connects the start switch to the clutch switch in the plastic wrap under the seat.
I'm a master mechanic but have almost no electrical experience on bikes. All mine were built like a Seiko watch; except.
They cut the outside rubber seal on the distributor bearing when they sat the head on my Yamaha 360 6 speed at the factory. So it had a slooow leak out the dist cover. This VS800 has always had the bad habit of the clutch fluid turning to pond scum. Rebuilt the master cylinder and that slowed it down. But I still have to replace it once a year. 
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1998 VS800 65,000mi Clutch Start
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