Author Topic: Kill switch bar steward  (Read 84 times)

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Offline Gorillastrom

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  • Bike: Suzuki DL650 V strom 2009
  • Location: Cambridgeshire
Kill switch bar steward
« on: October 13, 2025, 23:35:21 »
Hello everyone,
My 2009 v strom 650 threw the dreaded kill switch fault. Opened up the ignition assembly and found that the plastic insert with the copper contacts, had been burned and had broken into pieces. I acquired a new kill switch assembly from Japan and just forked out £220 for the mechanic to do the installation. All in all. An expensive repair. However, when I picked up the bike the dresser FI fault code and check engine light was on. Mechanic asked me to ride the bike as the fault code may clear itself. He said that a lot of panels and parts had to be taken off to install the new kill switch assembly, so the bike may just be ‘throwing a bit of a fit’. Well, I rode the bike home and noticed that at slow speed,it seems to stutter and almost cut off. To my untrained knowledge, it was a misfire. Needless to say the code didn’t clear and the error remained. How likely is it that the kill switch swap and the work needed effed up something else? As always, thank you for sharing your knowledge.

Offline nigel s

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Re: Kill switch bar steward
« Reply #1 on: October 14, 2025, 05:26:02 »
To answer your question...yes , very likely other connectors that may have been near to failing have now done so by being disturbed.
There is a lot of help on here to point a home electrician in the right direction...if you feel up to it .. :shrug:

If you can strip the fairing / tank off yourself , it takes no electrical skill to eyeball the connectors and the loom for obvious faults. Follow the new switch back and open any likely connectors one at a time as you go. Look for any burnt/ discoloured / loose or broken contacts . It may be obvious where the problem is. He may have also not reconnected the air box sensor or disturbed a fuel/ air line when removing the tank that is giving the  fault.
Costs nothing but your time to have a look.. :shrug:

If not happy to do that , take it back to your mechanic , if you trust him ? , not sure I do, but  I don't know him  :shrug:. He did the swap but should really have investigated the resultant fault . Even if  just to be able to give you a reason for it happening. Don,t expect any more time he spends on it to be free though , unless it turns out to be a problem directly with the new part or his mistake in not reconnecting something.
There is a relay kit available ( others will have to chime in as to where from , I have a gen 3 650 so not up on that ) to stop the kill switch/ headlight switch burning out again . But worry about that after sorting the present problem.

Sorry...All I have for the early model...

Offline Gert

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Re: Kill switch bar steward
« Reply #2 on: October 14, 2025, 06:59:03 »
https://www.vstrom.info/Smf/index.php/topic,7061.0.html is the route that I would follow.
Try identify the dealer mode code, look up the code cross-reference and that should help narrow down / identify which component is not being detected or is not send the correct information to the ECU.