The wiring is from the GT750 diagram, but will be valid for most of the Suzuki models.

I had some issues with the ignition switch on my GT750. It started as an intermittent fault, but by the next day, it completely died. I had to hot-wire it just to get the bike running. I did it like this:

By adding two wires to the switch connector located inside the headlamp, I was able to bridge the red and orange wires, leaving it open when the bike wasn’t running. Note: Be sure to insulate the wires with tape. Any contact with the frame will cause a short and blow the fuse. Doing so, it all worked except from the tail light, but the brake light was OK.

The next day I came home from my ride and could start to repair the ignition switch. This is how it was done:

Both the orange and red wire had bad connection to the terminals. In addition the red terminal was loos and I took the switch all apart:

The loose terminal was glued with epoxy and all the wires were replaced with new ones.

One of the insulation spacers was broken. The brown was OK, and I made the gray one from a PCB sheet. The material for the sheet / spacer has to withstand some temperature since all the current to the bike goes through the switch. I also added som grease for electrical connectors before the assembling.

All done and it worked perfect 🙂