Suzuki DF40 Kill Switch

[SteveHall]

I have a strange problem with a 2004 Suzuki DF40, The kill switch is intermittently stopping the engine when lanyard is removed

I have replaced the switch for a brand new Suzuki part, but the issue is still the same. Some times it kills the engine instantly as you would expect, other times it continues to run for 10+ seconds. Each time you pull the cord the plunger in the switch instantly goes back in so its like a strange electrical fault. The extended running is probably about 1 in 10 times.

Anyone seen anything like this?

[ShinyShoe]

very slightly loose connection somewhere in the circuit... vibration is making it close but can take 10seconds to happen?

[Poly]

Does turning the key off work 100% though?

[SteveHall]

yep - turning off with the key always stops it, and i never have an issue starting it.

[Poly]

Originally Posted by SteveHall

yep - turning off with the key always stops it, and i never have an issue starting it.

Presumably both wires share the same ground inside the contours box and loom - so it hints that the problem is somewhere in the wire between the switch and the engine.

[SteveHall]

Looks like a good few hours with a multi meter

[SteveHall]

Looks like it is the ground issue - anyone know where the common ground is? or have a wiring diagram.