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ARRRGGG Won't start - SOLVED (Read 16 times)
SeeAPierce
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ARRRGGG Won't start - SOLVED
11/28/06 at 13:52:48
 
All I did was replace the handlebars - honest! Embarrassed
It started perfect 20 minutes earlier.  I've changed the bars before without any problems.  This time when I was done, the bike won't start...  :'(

All the switches work: turn signals, high beams, hazards.  And the headlight goes out when I push the start button like it's supposed to ('06 model).  But no decompression solenoid and no starter motor.  dead dead dead.  When I turn the ingnition key, I can hear the neutral relay engage and the neutral light goes on.

I have pulled the seat and tank to check - everything is connected... ???

Does anyone have an exploded view of the right handlebar switch cluster?  Even though the headlight goes out I'm afraid I've lost something in that cluster during the bar change...

I've looked for step by step instructions on bypassing the neutral/clutch/stand system, but I can't find anything that's dumbed down to my level... Undecided
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vroom1776
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Re: ARRRGGG Won't start
Reply #1 - 11/28/06 at 13:58:39
 
clutch interlock:  rip off the two wires that go to the switch and solder them together, apply electrical tape.  makes it think the clutch is engaged.  Side stand relay is the same deal, I believe.  Open up the left side switch housing and check everything in there... that is my best guess.  Did you pull the tank off at all?  you may have picnhed a wire...

Oh, and!  does the brake light work if you grab the front brake lever?  if not, you may have disconnected that whole cable.  The connector lives on the right side of the frame, kinda under the tank.  you should be able to see it w/o removing the tank.  Make sure this connector is fully seated.
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SeeAPierce
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Re: ARRRGGG Won't start
Reply #2 - 11/28/06 at 14:20:59
 
I did just that with the clutch wires - didn't help.  I wasn't sure if the sidestand was the same, so I'll try that tonight.  What else is in the left side switch housing that could affect starting?

Brake light does go on when I pull brake lever.  And that cable connection on the right seems to be together, but I'm going to pull it apart and re-seat it tonight...Thanks!
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Reelthing
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Re: ARRRGGG Won't start
Reply #3 - 11/28/06 at 15:00:38
 
check the fuses
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Re: ARRRGGG Won't start
Reply #4 - 11/28/06 at 15:38:51
 
I'm not 100% sure the side stand is the same.  Take a look at the switch  when the side stand is down and up.  I THINK it pushes on the lever when it is down, so you'd want to make sure the circuit is open... I THINK!  I will try to check a wiring diagram and check my own ride tonight.

V
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Ed L.
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Re: ARRRGGG Won't start
Reply #5 - 11/28/06 at 18:36:26
 
The kickstand switch is a on when pushed setup so when the stand is up it pushes on the switch. Just cut the wires, strip them and twist them together to bypass it.
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Re: ARRRGGG Won't start
Reply #6 - 11/28/06 at 18:36:47
 
are there only two fuses?  If so, they're both fine.
Is there another?
Thanks

Reelthing wrote on 12/31/69 at 16:00:11:
check the fuses

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Re: ARRRGGG Won't start
Reply #7 - 11/28/06 at 18:46:50
 
I've now bypassed the clutch and the sidestand switches.  All other electrical connections seem to be tight and correct.  All switches seem to work including the start button as evidenced by the headlight turning off when pressed.  Bike is in neutral and neutral indicator is on.

I'm wondering if the start button hits multiple contacts, and perhaps even though the headlights are dimming the connection to the starting system is shorted out or broken...?

Ed L. wrote on 12/31/69 at 16:00:11:
The kickstand switch is a on when pushed setup so when the stand is up it pushes on the switch. Just cut the wires, strip them and twist them together to bypass it.

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Re: ARRRGGG Won't start
Reply #8 - 11/28/06 at 18:50:52
 
Here's another thing to check, there is a electrical connection under the right front of the tank on the main harness, check to see if it was yanked on while changing the handle bars. I pulled it loose on my '02 and it drove me nuts trying to figure out what went wrong. You can see it if you stand at the front of the bike and look along the top rail under the front of the tank.
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Re: ARRRGGG Won't start
Reply #9 - 11/28/06 at 19:04:39
 
Yea - thanks Ed...I checked that as well...It seems to be together - that's the same connector that contains the front brakelight wires...and they work fine...

[glow=red,2,300]this is driving me nuts!!! [/glow]

Ed L. wrote on 12/31/69 at 16:00:11:
Here's another thing to check, there is a electrical connection under the right front of the tank on the main harness, check to see if it was yanked on while changing the handle bars. I pulled it loose on my '02 and it drove me nuts trying to figure out what went wrong. You can see it if you stand at the front of the bike and look along the top rail under the front of the tank.

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Re: ARRRGGG Won't start
Reply #10 - 11/29/06 at 07:00:45
 
I've had the starter/turnoff switch apart on my bike, be carefull if you take it apart there are a bunch of little springs and ball contacts in it. Spread something out on the floor of the shop to catch whatever falls out. I found a piece of a bug stuck in the contacts on my bike so there is no telling what you could find. Can't think of anything else to check, it is probably something simple so keep looking and luck with it.
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Re: ARRRGGG Won't start
Reply #11 - 11/29/06 at 07:05:57
 
That is exactly what I'm worried about, that something popped out...I took it apart again last night and checked all the contacts, and everything seems intact.  I checked continuity through the switch to the connector, and everything seems to check out there.  But I've learned over the years, that just because you have continuity doesn't mean you have the correct electrical path without shorts.

I'm sure it is something simple that I just haven't found yet.  Does clymers have an exploded view of the switches?

Ed L. wrote on 12/31/69 at 16:00:11:
I've had the starter/turnoff switch apart on my bike, be carefull if you take it apart there are a bunch of little springs and ball contacts in it. Spread something out on the floor of the shop to catch whatever falls out. I found a piece of a bug stuck in the contacts on my bike so there is no telling what you could find. Can't think of anything else to check, it is probably something simple so keep looking and luck with it.

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Re: ARRRGGG Won't start
Reply #12 - 11/29/06 at 07:21:25
 
SeeAPierce wrote on 12/31/69 at 16:00:11:
are there only two fuses?  If so, they're both fine.
Is there another?
Thanks



that's them - might want to check the battery voltage for >12.3

but your saying you do not hear the decomp sol click?
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Re: ARRRGGG Won't start
Reply #13 - 11/29/06 at 09:49:58
 
That's correct - headlight shuts off, but decomp sol does not click...battery voltage is good @ 12+

Reelthing wrote on 12/31/69 at 16:00:11:
that's them - might want to check the battery voltage for >12.3

but your saying you do not hear the decomp sol click?

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Re: ARRRGGG Won't start
Reply #14 - 11/29/06 at 10:37:56
 
i dont recall the headlight turning off when cranking occurs, what is the voltage on the battery when attempting to crank? do we have an electrical diagram on this web site? or else i'll look in the book when i get home this afternoon
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