Ignition Switch Bypass

[azmsp84]

Alright, first post on this site. I've been searching for hours through my service manual and the forums trying to find why I can't get my 03 gsxr 600 started.

Let me start by saying that I am not using the factory fuel pump.

Also I do not have the harness for the gauge cluster so that is not plugged in.

Also, the Side stand switch, I do not have a diode in it, but it should run with the circuit open as far as I can see.
I have a running gsxr bike sitting right next to my rail and I'm seeing that I can start it without the gauge cluster and any position with the kick stand as long as the clutch is in or I am in neutral.

Oh also I don't have the rectifier right now either but the diagram only shows power and ground going in and then straight to the generator

I also do not have an ignition switch, I am trying to bypass it. Nothing in the manual says anything about diodes or resistors, but I have a feeling there may be one. What I have done is taken Red and Orange and spliced those together, taken O/Y and B/W and spliced those together, as well as Gr and Br. I finally got to the point where I can flip my starter switch and it cranks over but I don't have spark. I have the TO sensor mounted properly (I think) it say up and its up.


Any ideas? Thanks in advance!!! Rich.

[rowycoracing]

Welcome to MBN!

Yes there is an anti-theft cricuit in the key switch so that someone can't just hotwire the bike. There should be a lead going back to the EDU that is the anti-theft circuit. It needs a resistor. Do you have the wiring diagrams? As long as the bike is in neutral and/or the clutch is in (clutch switch activated) the side stand switch won't stop you. It will only kill the engine when you try to put it in gear if it thinks the side stand is down.

[azmsp84]

Cool, I ran across this info on gixxer.com forums. I figured a race bike setup would be identical to out situation. Hope this helps others out.


Re: Race Wire Harness
as far as the key what you need to do is this:

Parts:

100 Ohm Resistor, 1/2 watt, 5% tolerance: Radio Shack part 271-1108
18-20 Gauge Wire (two different colors)
Electrical Tape

I soldered all of the connections. If you would rather use connectors and
a crimping tool, you will need to have a supply on hand. I am not sure how
one would install the resistor with out a soldering iron.

------------------------------------------------------------------------

Here is the legend for the various wires involved in the re-wiring:

Wire Colors and Functions (Right Handle Switch (Kill Switch)):

O/B (Orange with Black Tracer) -- Kill Switch
O/W (Orange with White Tracer) --

Wire Colors and Functions (Key Switch):

Br (Brown) - Tail Light
B/W (Black with White Tracer) - Ground
Gr (Gray) - Instrument Cluster Light and Horn
O (Orange) - Ignition
O/W (Orange with White Tracer) - Cooling Fan
O/Y (Orange with Yellow Tracer) - ECU
R (Red) - Power (+12v)

------------------------------------------------------------------------

Removal:

The first step is to remove the two wiring harnesses that will be
modified: the key switch and the right clip-on switch cluster. Find and
disconnect the connectors that connect these harnesses to the main wiring
harness. The key switch has two connectors along the right frame spar.
The right clip-on switch cluster has a connector just in front of the
radiator on the right side. You will have to open some zip ties and a
clamp to get the harnesses free.

To remove the key switch, you will have to take off the top triple clamp
and remove the two tamper resistant Torx bolts. I do not have the correct
Torx bits so I drilled the heads of the bolts off. To remove the right
clip-on switch cluster, you will need to disconnect the throttle cables
from the cluster.

------------------------------------------------------------------------

Key Switch Harness Modification:

This one is actually quite simple. Start by cutting all the wires 2" from
the main connector. Cut the Br and Gr wires at the connector so they are
slightly recessed since they will not be used. Cut the O/Y and B/W wires
to 1" in length and solder a lead of the 100 Ohm resistor to each wire.
Insulate the wires and resistor with Electrical tape to keep the O/Y and
B/W wires and resistor leads from touching. Leave the R and O wires at 2"
for now.

------------------------------------------------------------------------

Right Clip-on Switch Cluster Harness Modification:

The goal here is to re-wire this harness so the circuit the kill switch
normally controls is always connected (run) and to have two wires coming
out of the harness connected to the kill switch.

In the run position, the kill switch completes a circuit between the O/B
and O/W wires. The O/W wire actually connects to the starter button and
the kill switch. A "Y" is formed about 4 inches down the wiring harness
from the switch. Cut into the sheath and find where the O/W wire forms the
"Y" and cut the O/W wire that leads to the kill switch. Cut the O/B wire
at the same point in the harness and solder it to the O/W running to the
Starter Switch. Run a pair of wires through the sheath and connect them to
the O/W and and O/B wires from the kill switch. Leave about 3" of wire
hanging out from the sheath at the connector end. Use electrical tape to
insulate all of the connections and to cover the cut in the sheath.

------------------------------------------------------------------------

Putting it All Together:

Take the key switch harness and right clip-on switch cluster harness
connectors and plug them into the corresponding connectors on the main
wiring harness. Look at the R and O wires coming from the key switch
harness and the two unconnected wires coming from the right clip-on switch
cluster harness. If needed, cut the appropriate amount of wire from the
right clip-on switch cluster harness to allow for an uncluttered
connection.

Unplug the key switch harness and right clip-on switch cluster harness
connectors. Connect the R wire from the key switch harness to an
unconnected wire from the right clip-on switch cluster harness. Connect
the O wire from the key switch harness to the other unconnected wire from
the right clip-on switch cluster harness. Use electrical tape to insulate
all of the connections.

Put the kill switch in the "stop" position and plug the connectors in
again. Put the kill switch in the "run" position. The bike should power on
and be ready to start. Try starting the bike. If it starts, you are just
about done.

------------------------------------------------------------------------

Finishing Up:

Reinstall the right clip-on switch cluster and clean up the wiring harness
connections.

[crazyawesome]

Man thanks, I was just having the same trouble. Man thanks for saving the day....

[azmsp84]

Not a problem, I hate it when people have problems I have, find the problem, and then never share. I see this is stickied already, glad to help everyone out.


FYI just fired it up, that writeup worked like a charm. No rectifier, gauge cluster, or fuel pump installed at the moment.

[Wild Earp]

Does anyone know how to do the same thing on a 05 R1 motor? The ignition switch doesnt have a ground wire..