Electrical Problem - nothing happens when I depress the start button

[Chris2P]

Took bike apart to rejet carbs.

Also replaced handlebar and left hand switch ( lights, horn,turn signal)



Now when I press the START switch nothing happens?

Lights, horn, turn signals work.

I began the troubleshooting sequence in the Clymer manual.  Fuse good, brand new battery.  But................Can't find how to test the start switch - on/off switch in the Clymers manual.  Troubleshooting section refers  to the  Switches section and Switches section only tells you how to replace the right hand switch.  Does anyone know how to test this switch?

Rule outs:

Side stand is up (I havent tested this switch yet because the wire goes directly into the switch and I dont see how it can come out.  I guess I can test it on the other end of the wires where it has a plastic connector?)

Clutch safety switch - I never had one since I bought the bike new.

Main fuse good ( I guess the lights, horn, turnsignals wouldnt work if it was blown)

battery, brand new.  Bike started right up after the first time I cleaned my carbs this year.

Any help would be appreciated.  I did do a search and most threads diag lead back to the clutch safety switch which my bike doesnt have.


Chris

[3imo]

Clutch safety switch - I never had one since I bought the bike new.
Any help would be appreciated.  I did do a search and most threads diag lead back to the clutch safety switch which my bike doesnt have.
Chris

you sure about that? you bought the bike new? wierd.  what year is the bike?  I would guess it was bypassed somewhere. maybe when you tore the handlebar apart you dislodged the short someone used to bypass the switch.

either way the bike was built with the connector to recieve the switch input. find that and short it out.

what year is the bike?

[LimaXray]

If you messed with the handlebar, I'd suspect the single wire connector on the yellow/green wire coming from the right hand grip.  Make sure it's connected and isn't damaged.

To test, find the starter relay and the same yellow/green wire coming from it.  Touch that wire to the (+) terminal of the battery and see if it cranks over.  You may need to get yourself a piece of wire to go from the wire terminal to the battery, but that will show you if the problem is with the starter/relay or the kickstand switch/starter switch/etc.

[Chris2P]

It's a 1990.

When I saw Kerry's post I figured that I probably forgot to reconnect the clutch wires.  Didnt remember taking them off but you know my memory isnt that sharp:-)  I went back and lookes like the connecor has a cap or something on it.  Doesnt look like i took it apart and I fished for a long time to try and find a hanging wire.  But nothing is there.  I'll try and take a pic. Thanks for the fast reply.

Chris

[Chris2P]

LimeXray,

Thanks,

Will try that right now.

Chris

[scratch]

Red switch on right handlebar set to Run?

[LimaXray]

lol yeah that will do it... also make sure it's in neutral just incase the sidestand switch isn't working.  If you do the wire test, do it with the intent to start the bike.  If it starts or not also narrows down what the problem can be.

[3imo]

this might help

[LimaXray]

i have that bad boy saved to my desktop 

[Chris2P]

Limaxray,

I bought some wire and sure enough, the starter turns over when I attach it to the yellow green wire and the battery.  Can I assume that the starter relay is OK by this test?


..............yes, I made sure that the kill switch was on:-)................


Kewl diagram, I think I'll print that bad boy out and get it laminated    thanks!!!!

I guess that this narrows it down to:

start - on/off switch

side stand switch

anything else?

Looking at the diagram, if I unplug the right hand switch socket in the headlight assembly and attach a multimeter to the orange/blue wire and the orange/white wire I should get continuity, right?  And if so, make next step should be to attach the mulitmeter to the orange/blue wire and the yellow green wire and i should get continuity when I depress the start button.  Am I right?

[LimaXray]

Yes, the starter relay and starter are fine.

Could you start it like that? Put the side stand up, put it in neutral, flip the kill switch to run and try to start it up with the wire

if you can start it, it's either the starter button, the clutch switch, or one of the connections.  If this is the case, do a continuity test between the yellow/green wire at the starter switch and the starter relay.  Try squeezing the clutch to see if that changes anything.  If you get continuity, then check the starter button as you described.

If you can't start it, its probably the sidestand relay, kill switch or one of the connections.  The bike will start and run with either the side stand up or the bike in neutral, I doubt both switches would fail.  In this case, check that you have 12v between the orange/blue wire you mentioned and ground when the the kickstand is up, the bike is in neutral, and the ignition is on.  If you do, check your kill switch as you described.  If you don't, let us know.

[3imo]

LX is on the money. 

I have a suggestion though to save time,  since you have the light bucket tore apart just ohm out the switches one by one.

attach the multimeter and if the ohm reading changes when you operate the switch you can rule out each individual switch and corresponding circuit one by one.

if all works then concentrate on what switches are in parellel and the coresponding wires.

LX's suggestion will work just as well.

[Chris2P]

There is no clutch switch (I vaguely remember now that I removed it about 13 years ago when it was giving me trouble )

I have continuity on the engine stop switch when its turned on.

I DO NOT have continuity on the starter switch  (orange/blue wire and yellow green wire, or orange/white wire and yellow/green wire) when the stop switch is turned on, the sidestand switch is on (side stand up) and when the starter switch is depressed.  I also attached a 12 volt testing light from the yellow/green wire from the starter switch to the negative battery terminal.  I assumed that if the tester did not light up when the ignition is turned ON, kick stand up, stop switch on and starter switch depressed that the starter switch is bad   ie.. I should have had current, right? 

And yes I tested the testing light before using it on the starter switch.


Chris

[LimaXray]

Well if you can't get continuity across the starter switch when it is pressed, then that right there is your problem.  Try using a small piece of wire to jump the starter switch by going from the orange/white to the yellow/green wire.  If it turns over and fires up then your starter button is 100% shot.

[Chris2P]

YEEEEEHAAAAAAA


LimaXray,

That did the trick!!


Just ordered a new start switch.


Thanks LX and everyone for your help.  I owe you all a beer


Chris

[LimaXray]

I'm glad you got it figured out 

mmmm a beer does sound good right now