1995 Katana 750 stalls while riding!!! HELP

james30263 · 09-09-2007, 9:38 PM

I have a 1995 Suzuki Katana 750 that normally runs great, but lately when I go riding the bike will stall now. This seems to happen when I've been riding for atleast an hour +. What happens is i can be riding anywhere from 60 to 80 MPH when out of the blue everything just dies. The instrument panel, lights and motor die. The weird thing is that some times I can kick it into neutral and restart the bike while still moving. Everything only shuts off for seconds in most cases. At first I thought it was over heating but I've changed my mind since then. I've checked the battery (Good clean tight connections) and the voltage while revving the RPM's to 5000. The voltage reads 15.3v so that seems to be good. At idle it's around 13.5v. After checking that I checked the kickstand switch to see if that was killing the motor and yes it will kill the motor but when I tested this the instrument panel still was operational and the lights were on. Has anyone ever heard of an issue like this? Any help you could give me would be greatly appreciated.

9two9rider · 09-09-2007, 10:54 PM

Had the same thing happen to my 929 on my way to Bike Week '06, but mine never restarted. I can't tell you it's the same repair, but I replaced the wiring harness. Never had another problem with it.

arlenmarvin · 09-10-2007, 2:10 AM

Hi, I hope you have fixed your bike but if you haven't I would check the ignition switch, and the wiring harness connections from the battery to the ignition switch. Ive had connection problems with both. Washing and rain causes switches and connections to corrode. The ignition switch is most likely one. Good luck,

james30263 · 09-11-2007, 9:17 PM

I went and checked the ignition switch and it looked to be in great shape. Next I checked the wiring coming from the ignition switch and thats where I found the connector that connects the ignition switch to the wiring harness was melted. I replaced that connector and checked the rest of the harness. In doing so I found two pinched wires and repaired those as well. The bike doesn't die on me anymore but now I have a new problem. Everytime I either hit the kill switch or turn the key to the off position the main fuse blows. NOTE... It only does this after I ride it for a little while. If I warm it up and immediatly turn the key off or use the kill switch it wont blow..... Have any ideas for this? ALSO...Thanks for your help on the other issues...

arlenmarvin · 09-12-2007, 1:54 AM

Good question,,,hmm Did you possibly get some wires mixed up or assemble the ignition switch incorrectly? It sounds as when you put it to off position it goes directly to ground creating a dead short. Good luck!

Quote:

Originally Posted by james30263

I went and checked the ignition switch and it looked to be in great shape. Next I checked the wiring coming from the ignition switch and thats where I found the connector that connects the ignition switch to the wiring harness was melted. I replaced that connector and checked the rest of the harness. In doing so I found two pinched wires and repaired those as well. The bike doesn't die on me anymore but now I have a new problem. Everytime I either hit the kill switch or turn the key to the off position the main fuse blows. NOTE... It only does this after I ride it for a little while. If I warm it up and immediatly turn the key off or use the kill switch it wont blow..... Have any ideas for this? ALSO...Thanks for your help on the other issues...

james30263 · 09-12-2007, 10:23 PM

Well my buddy came over today who is really good with a multimeter. We checked the resistance on the bike to check for an open circuit and found none so that eliminates a ground issue. We narrowed it down to the voltage regulator on the altenator. One side of the fuse shows 12.6 volts (The battery side) and the other side of the fuse was reading 16 volts Thus showing that the altenator (regulator) is trying to push to much power thru one side of the fuse and melting it. This is why the fuse is popping. After doing this we put 2 and 2 together and realized I had one big f%$#ing problem! The regulator isnt regulating the voltage that the altenator is pushing out. (Hence the name "VOLTAGE REGULATOR". I'm going to replace the regulator and I think that this will solve my problem. I hope that this will help others with their issues in the future. Thanks for your help guys.