Motorcycle Repair: Overheating, exhaust leaks, electrical diagnosis

Question
I own a 2002 Suzuki Bandit 1200s, The problem is I started the bike up and left the choke on at approx 2500-3000rpms for about 15 mins.  I know I know! Bike had shut off by the time I returned.  Pipes are discolored and smoke was rising from the engine.  Now, the green indicator light for the neutral switch is not working properly, as in sometimes it comes on others not at all.  I can't start the bike in neutral unless I pull up kickstand and pull in clutch.  I immediatly changed the oil by the way.  Also, I can start the bike let it run with the choke on, as soon as I choke it down and roll the throttle it dies.  As it runs the green indicator light will start to flicker and then disappear, even though I never take it out of neutral.  Once that happens, I can not start it again unless I lift the kickstand and pull in the clutch.  Is it possible I melted a electrical connection?  As far as the running goes, I'm at a loss, I'll check the plugs and look for melted plastic connections.  Any advise will appreciated.  Thanks.

Paul Fricke

pfricke000@centurytel.net

Answer
Hi Paul,

It happens.  

I agree with you and also suspect the high temps caused some type electrical defect. Hopefully it's a conductor connector and not an expensive component.

Things to do:

1) Replace the spark plugs.
2) You've already changed the oil, good thinking.
3) Check cylinder compression. Follow with a leak-down test if compression results are out of service limits.
4) Listen for exhaust leaks. Replace exhaust gaskets if necessary.
5) Perform electrical diagnosis. Look for obvious evidence of heat damage. Melted, discoloration, brittle insulation, etc...
6) Check for oil leaks or seepage on the cylinder and cylinder head areas.

I think you already have good investigative skills, just need reassurance. Keep me posted on your progress. I'll send tech files to your email address, thanks.

Respectfully,
Mark Shively