GS1200SS inspection, Newtech oil change, fluid exchange, axle shaft replacement, and troubleshooting for a power-on failure that occurred twice.
We got the wiring diagram and tested various points. With the key OFF to ON, nothing lights up. No lights or electrical components work at all. When I fiddled with the connectors, the system seemed to come back to life—twice.
I wondered if that was even possible and checked, but… it shouldn’t be. However, looking at the wiring diagram, there were only two connectors where this could happen.
The starter relay and main key—two locations. We found no issues, but we removed them, cleaned the contacts, and reinserted them firmly until they locked. It’s tough to diagnose when the symptom isn’t showing up. We replaced the axle shaft with the one that was brought in. Suzuki oil-cooled fork spans are 205 and 200, but they’re interchangeable. When we remove the fairings, cleaning hard-to-reach spots makes a real difference in how much dust accumulates next time. We changed the fluid to CCI Golden Cruiser DOT4 and replaced the engine oil with NC50 10W-50 and a new filter. That completes this service.
