Hi all, just bought a '89 GS500E and Im pretty excited to starting riding once warmer weather comes around. Upon unloading the bike off the truck, I tried starting, but naturally in 20 degree weather it cranked slowly. I decided to jump it off the truck battery because I figured it would be quicker to ride it up the long driveway than to push it. After hooking up the jumper cables, the bike wouldn't crank over. Headlight and everything else still works. I'm a car mechanic by trade so I have the tools and knowledge to figure it out, just thought it would be easier to stop in here and see if this is a common problem with these bikes. I did a quick search and didn't find much to help me. Thanks for the help!
For bike to run, it must be in neutral or the side stand up. So insure you're in neutral.
There is a clutch safety switch. It is wired in series with the starter button. Did you pull in the clutch? (Some bikes will start in neutral without pulling in the clutch, but not the GS500)
Kill switch on the right handlebar?
The other night i went to start it in the bed of the truck, and even though i was pulling the clutch all the way in, the bike still lunged forward indicating it was in gear. AFter finding neutral it started fine. Today while unloading it, I was having a hard timing finding neutral. There wasn't a clear "crisp" click in between gears, Im not even sure it was shifting. It once again lunged forward while trying to start it today. After rolling it down the ramp, I finally got it into neutral while trying to jump it and thats when it started acting up. I don't know if maybe something happened while rolling it in gear or trying to start it in Gear. sounds like maybe the neutral safety switch has been by passed. thanks for the help adidasguy
If in neutral, is the green neutral light on?
Check the right hand kill switch. It can get bumped if you don't think of checking it, bike won't run.
Do you hear the starter relay click?
Remember - the clutch lever MUST be pulled in - even when in neutral.
If the clutch is in, kill switch in the ON position and no click when pressing the start, open up the headlight bucket.
The clutch safety switch is in series with the start button. The safety switch and start button connect in the headlight bucket. Each has 2 wires and a male & female bullet connector. IF the safety switch is bad, you can unplug its wires and connect the 2 wires from the start button together with the barrel connectors, hence bypassing the safety switch. (I think the wires are yellow with green stripe)
No neutral light, but I think its probably just burned out. The "oil" light is illuminating though. I've been pulling the clutch in all the way every time. Im not hearing the starter relay click, and the red switch is on "run". Im thinking the clutch needs adjusted, because the bike would still jump when i tried to start it in gear even though the clutch was pulled all the way in. So its not disengaging all the way. But it doesn't make sense why it would stop cranking all of a sudden when i tried to jump it.
It should be easy to trace the start button to the starter relay and everything else. On the 89-00 models everything connects in the headlight bucket.
Clutch plates stick together. It is a wet clutch. Even pulling in the clutch lever will not disengage fully a bike with sticky plates until the bike runs a few seconds and fresh, warm oil is bathing the clutch. That's why neutral is best for starting the bike.
Neutral switch connects under the seat (single blue wire connection). It makes a connection to ground when in neutral. You can check that with a meter.
You can short the terminals on the starter relay with a screw driver to get the starter motor going (if all else fails).
(http://i47.photobucket.com/albums/f191/eimoytiana/wire.jpg)
Awesome, just the information I was looking for. Thanks a lot, I'll let you all know what I find out once its not so cold outside and I can actually stand to work on it for more than 5 minutes. :thumb:
There is only one fuse in a GS500. It can be various places on the 1989 model.
There is always a spare so do not confuse the spare with the real fuse.
and since ANY light comes on, the fuse is not burnt. Then the fuse goes, nothing lights up.
you might have also been in a false neutral (between gears), you can shift with engine off and no clutch by rocking the bike back and forth. keep shifting down till you find first gear, then slowly lift the shifter while gently rocking to find neutral all with your hand off the clutch. now you have a couple of safety interlocks, one is the clutch lever switch, the other is on the kickstand. ive disabled both mine. another culprit could be the engine run/stop switch on the right control group (the big red rocker switch) while its been awhile tracing wires, mine wont crank if that switch is in stop position.
Turns out the bike was in a "false" neutral. Now that the bike starts just fine. I did let it warm up for about 10-15 min and everytime I squuezed the clutch and put it in gear it lunged and died on me. And clutch adjustment on these bikes?
is there alot of slack in the cable? adjustment down on left hand side above the gear shifter and on left handle bar lever. now, there is a tiny cover just above the shifter that houses the clutch actuator and pushrod. been awhile since i looked, but i think there is a adjustment screw and lock nut behind that. but check the cable slack first.
Do a complete 3 point clutch adjustment to get it right. From shop manual:
http://www.gs500.net/gallery/data/500/GS500_clutch_adjustment.jpg