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Bandit Fuel/Vacuum Lines , Wiring and Flywheel

Discussion in 'Suzuki 250cc In-line 4's' started by Joker, Feb 16, 2014.

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  1. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    Phil : Is that the only wire connected to the - battery terminal?
     
    GreyImport, Feb 23, 2014
    #41
  2. Phil

    Phil Senior Member Contributing Member

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    No, there is a small black and white wire that feds back into the loom. It's not easy to see as the bandit has the seat latch connected directly above the battery, try getting that out in a hurry.:lolsign:
     
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    Phil, Feb 23, 2014
    #42
  3. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    Yea the ZXR has the seat latch right over the battery also.

    Well maybe Im wrong in identifying that large black cable Stu originally asked about? ..... to me it looks like its just laying on top of the starter motor , as the starter cable is to the left of it.
    I wonder what connection type is under the rubber boot end that he has circled....?

    Phil , do u have a cable anywhere that looks like that?
     
    GreyImport, Feb 23, 2014
    #43
  4. Phil

    Phil Senior Member Contributing Member

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    Mine is the same, the cable in question goes from the starter motor to the starter solenoid which is just behind the battery box. Then it crosses over to the positive side of the battery. The connection on the starter motor has a bolt coming out of the starter motor body to which the cable is fastened via a nut and washer.
     
    Phil, Feb 23, 2014
    #44
  5. Joker

    Joker See "about me" for contact details. Contributing Member

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    Here's another photo from the bike... The one I am holding is the wire in question. The one towards the bottom (on the relay) is the one that connects to the back of the starter motor, as shown in an earlier photo...

    It just doesn't make sense to me that this is anything but the battery earth. The battery is only grounded now through the starter relay as there is only the single connection to the -ive terminal. But I just want to make sure I'm right lol

    DSC_0224.jpg
     
    Joker, Feb 23, 2014
    #45
  6. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    Can u pull back this rubber cap and show what the connector looks like? ...I bet its a battery terminal shaped connector.

    Rubber cap.jpg



    These are the main + connections/leads to the starter solenoid ....

    Starter.jpg
    Starter lead 2.jpg



    Both those main connections on the starter solenoid are +

    From starter.jpg

    Now this is an earth ..... where does this go to ?

    Earth.jpg

    Does that metal connector thing on the - batt terminal go to the earth lead at the fixing bolt of the starter? .. as above


    Batt neg.jpg
     
    Last edited: Feb 23, 2014
    GreyImport, Feb 23, 2014
    #46
  7. Phil

    Phil Senior Member Contributing Member

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    The square rubber connector circled in yellow goes to the s/motor solenoid. The connector coming off the bottom of the s/motor goes to - of the battery as you have marked with a red square in your last photo.
     
    Phil, Feb 23, 2014
    #47
  8. Phil

    Phil Senior Member Contributing Member

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    Here is a photo of mine, same as Stu's apart from I have no cover on my fuse box.

    002 (480x640).jpg
     
    Last edited by a moderator: Feb 23, 2014
    Phil, Feb 23, 2014
    #48
  9. Joker

    Joker See "about me" for contact details. Contributing Member

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    Ok so we don't get confused, the wire on the starter motor, shown by the red box below:

    Earth.jpg

    Goes to the starter solenoid, shown by the red circle below (not the one I am holding). It does not connect to the battery terminal directly:

    Batt neg.jpg

    As for underneath the rubber on the wire we are talking about, it looks like this:

    Engine side.JPG

    I'm thinking it may go to the bolt I have circled in the above photo, but I'm not sure. The hole in it is rather small although the wire does look thick enough to be an earth wire.
     
    Joker, Feb 23, 2014
    #49
  10. Phil

    Phil Senior Member Contributing Member

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    Hey Stu
    I am a computer nob, therefore trying to put circles or arrows is a tad beyond me.
    1) the wire with square rubber cap on the starter motor goes to the starter motor solenoid.
    2) the wire at the bottom of the starter motor goes to the -(negative) side of the battery.
    3) the wire you are holding in your had doesn't exist on my bike. It certainly looks like it should fit to the battery due to it's curvature, however no such wire can be found on my 400 Bandit.
    Over to you amigo, I have nothing more for you. Keep us posted.
     
    Phil, Feb 23, 2014
    #50
  11. Joker

    Joker See "about me" for contact details. Contributing Member

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    lol no problem :)

    Yes I'm honestly not surprised. I may just hook it up to the battery -ive and put the other end on the frame or engine casing somewhere. Can't hurt anything I suppose.

    The 400 manual has this in the wiring diagram, so...

    batt.JPG
     
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    Joker, Feb 23, 2014
    #51
  12. Phil

    Phil Senior Member Contributing Member

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    The earth wire does have a small black/white coming off it and found it heading back into the loom.
     
    Phil, Feb 23, 2014
    #52
  13. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    Phil has summed it up well.

    Some bikes have earths to the subframe and to the engine .... extra earths wont do any harm

    Just do as u noted above and run the spare one from the - battery to the engine casing.
    If it fits put the end that has the rubber cover over the battery terminal.
     
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    GreyImport, Feb 23, 2014
    #53
  14. Joker

    Joker See "about me" for contact details. Contributing Member

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    Sweet thanks guys. Yeh I'll do that, I've tested the SM so I know it works fine the way it is wired up so no need to mess with it.

    Just a thought - I seem to be missing a pressure fitted tube into the petcock for one of the lines. Is this an easy enough thing to repair or should I source another?

    DSC01068.JPG
     
    Joker, Feb 23, 2014
    #54
  15. Joker

    Joker See "about me" for contact details. Contributing Member

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    Hey guys... should I be concerned about the below? looks like someone drilled an inspection hole in both sides of the engine. Do I umm plug it with something?

    2014-03-03 18.26.46.jpg
     
    Joker, Mar 3, 2014
    #55
  16. Phil

    Phil Senior Member Contributing Member

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    Just checked mine, have no such hole. However mine is a VC engine model. Can't help you amigo.
     
    Phil, Mar 3, 2014
    #56
  17. Murdo

    Murdo The Good Doctor Staff Member Contributing Member Ride and Events Crew

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    Are the holes threaded?
     
    Murdo, Mar 4, 2014
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  18. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    Looks just like a casting hole or something from the factory

    Hole.jpg
     
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    GreyImport, Mar 4, 2014
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  19. Joker

    Joker See "about me" for contact details. Contributing Member

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    Hmm ok. I just find it interesting it seems to go all the way through to the piston chamber. I would have thought that's not a good idea in case water or something got in there... guess I could plug it with some gasket goo or something. No it's not threaded. I've seen the spot on the side before but I've never seen a hole in the spot before heh.

    I suppose I was just concerned it may do something to the compression... spose I'll find out soon enough .
     
    Joker, Mar 4, 2014
    #59
  20. Joker

    Joker See "about me" for contact details. Contributing Member

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    Well... I tried to kick her over today and she didn't do much. The starter motor is working but I think there's either fuel starvation somewhere or she's not getting spark. Plugs and HT leads are new and I tested the coils (both primary and secondary) and they seem fine. Made sure there was fuel flowing but not sure why I'm not getting a bit more life. Battery is back on charge after fiddling a bit but open to ideas if there's something I should specifically try to look at...?
     
    Joker, Mar 8, 2014
    #60
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