if i Jump the starter switch, is the spark killed? or could i potentially start it that way? and DoD#i i have been reading your other link, its very helpful, ty so much! Ill get the GF to bake u guys some cookies or something when i get this baby started! 

If the ignition is on, and the kill switch is on, and the kill switch works, you should have spark. I started mine that way when I needed to move to a garage in order to have it under cover while I ripped it open and solved its issues.

I highly recommend printing out both electrical diagrams and having them in the garage with the victim/patient.

is it getting any juice at all?  This might sound simple but my bike did the same thing and it's an 05 never sat. One minute ran fine next minute nothing at all. noi headlight blinkers gauges etc.  so i thought battery was dead so i push started it and it ran but horrible.  tach was up and down no light still and would die if i let the rpm's get too loww. ............found out my 20 amp fuse was blown

Quote from: Blackgk on August 28, 2008, 05:32:18 PM
The battery actually charged! I put it in, all the lights are super bright, turn signals work etc, hit the starter button, and nothing.

Quote from: souljeroflight on August 28, 2008, 06:26:40 PM
is it getting any juice at all?  This might sound simple but my bike did the same thing and it's an 05 never sat. One minute ran fine next minute nothing at all. noi headlight blinkers gauges etc.

He's got juice, see quote above yours. The failure has to be either to/at the kill switch (won't crank, won't run - the crank side is fed by the kill switch) or in the starting circuit (where it will run, since running only requires power to/from the kill switch).

ok well im going to pull a plug out, ground it, and see if there's  spark....

OK, with the spark plug grounded to the cyl head, i have good spark! (and as a bonus it looks like they have been burning well) that rules out the kill switch correct? I removed the side stand kill switch from the chassis, but it does not seem to have a connector there that can be accessed, just a wire that goes up under the air box some where, so i was not able to bypass it, as for the clutch switch...where is it? LOL 

  Woot! Primed it with some fuel, gravity fed, jumped the solenoid, and started right up! And I mean it purrs! Idles and starts better then my R1 lol, and I'm not kidding! Thanks to you guys! I would have been hopelessly lost without your advice! I still need to trouble-shoot the will not crank issue, and the GD gas cap fiasco, but its a real load off my mind to hear it running, and running so well.

Quote from: Blackgk on August 28, 2008, 06:48:30 PM
as for the clutch switch...where is it?

Look for the wire (and screws) under the clutch lever (near the pivot - not in the turn-signal/horn/high-low block) - or - pull open the headlight and look for yellow/green wires. Two together in one small black jacket are the clutch switch, the things those plug into are how you bypass, as I've already described. Under 5 minutes if you can get the headlight screws to move without breaking/stripping the heads.

Glad you got it running. I'd bet the clutch switch or that your "new" relay was the "bad" (yet saved) relay. Or both relays are good, and it's the clutch switch, which is by far the usual culprit, so bypass it before bothering to swap the old relay back in.

Im done for the night, ill track down the clutch switch tomorrow, im thinking its probably the clutch or sidestand switch, and the guy just went a bought the starter relay thinking thats what it was, for all i know he was "bump-starting" it when he parked it. On a related note, i managed to break the key off in my already screwed up gas cap, its now pretty much a write-off. Ill just look for an aftermarket keyless type assembly, or see if i can track down a used OEM unit (anyone have one they would sell?). Anyway, thanks a million, Ill post some pics later and keep you posted, 

PS anyone in Ontario or close by interested in a great poker run for a great cause, please check out my website www.chrisgarrettride.com

Peace

Blackgk

DoD#i, your the man! Pulled the saftey switch out of the clutch lever...I knew i was on the right track when corrosion was falling out of it before i even got the screws out...it was full of corrosion. I jumped the switch, hit the starter, and it fired right up! Didnt even have to get into the dreaded headlight housing. Next move is to see if i can clean and re-assemble the switch, or i have to replace it. Either way I'm laughing. You saved me a ton of time and a fortune in diagnostic time if i had to bring it to the dealer to get trouble-shot.

Thanks a bunch. I'll post some pics and stuff when i get it together, show ppl how nice a $600.00 bike can be!

You are welcome. 

Sweet, the switch it self was actually in surprisingly good shape. Just cleaned and re-assembled and it works fine. Discovered the clutch cable adjustment knob/threaded assembly was broken at the lever pivot, ordered a new cable. It still works because it just pulls tight against the broken half, but the bike is going to a new rider so i want the clutch to be as compliant as possible...

If anyones interested, I found a gas cap, the seller had me take some measurements and assures me it will fit, the price is very reasonable.

http://cgi.ebay.ca/ws/eBayISAPI.dll?ViewItem&item=250287070989&ssPageName=ADME:B:EOIBSA:CA:11

will advise when it gets here as to quality and fitment.

edit - it fits, and great quality!

Just got back from my first ride on the GS, couldn't be happier. Had a shaZam! eating grin on my face all day!

Here's what i have into it:

Bike as is $600
Battery $60
Fuel lines/filter $20
oil/oil filter $20
air filter $35
awesome info and advice from the GStwins.com community = priceless

Bike is super fun to ride, comfortable, handles well, and is the easiest bike to ride I have ever been on, just feels natural in every way, love the little engine with power in all the right places. Makes e never want to get on my R1 again.
This winter I'm going to pull the tank and bodywork off and have it painted the same blue as my Yamaha (yamaha blue or electric blue), the silver frame will really set it off I think, as well as some cosmetic work. I hope the GF enjoys riding it (it's going to be her first bike) cause it would break my heart to sell it, it's really becomme my little baby. Here's some pics as it sits now, with just the mechanical work done.





Big thank's in particular to DoD#i, who was a big help, I'll keep you all posted!

Looks sweet, glad I was able to help, you're welcome, and let's  sometime when I'm that way or you're this way or we're both some other way. Though it jives poorly with riding anywhere afterwards...I sure in the heck don't unless what's in the glass is ginger or root beer.