Ok guys so i pulled my old engine and dropped in another with less than half the mileage. this engine came from a bike with carb issues and it would turn over in the old bike. However, after putting it in mine and hooking everything up, the bike doesn't start. the engine doesn't turn over at all. I was wondering what i could have done wrong? I pull the clutch handle in and press the start button and theres nothing. not a whisper. so im thinking it must be something electrical? the engine was from a 2004 and mine is a 2005 and it looked like all the electrical plugs matched up perfectly. But maybe i need to take the signal generator from the my bike and use it with the new engine? because i used the signal generator that came with the new engine. Any help or ideas guys? thanks.

Any lights come on when you turn the key?

If you don't even get that, then check the fuse. 

- Bboy

Signal generator is the same.
Lights come on - yes or no? If no - fuse? Battery connected? Ground wire connected to motor?
Of nothing, is there a click for the starter relay?
If no click, check the kill switch? Neutral switch? Side stand switch? Clutch switch?
Is the ground wire connected to the motor?
Wire connected to starter motor?

just went down and checked a few thing guys. The oil light and neutral light both come on. The headlight and turn signals do not. Not sure why that is. Is my battery dead? idk how to check the fuse on these bikes. i also dont know how to check the clutch switch or where its at. but i think the headlight and sinals mnot coming on could be a clue. everything else seemed fine.

Bet its your battery then.

You can confirm with a Multimeter, or just charge the battery and try again. 

- Bboy

Yeah, go back and check, double check and triple check all the connections. Make sure your ground is good too!

Everyone should be required to have a Haynes or Clymer manual (I prefer haynes because the wiring diagram is in color).
    ...and just after that is everyone must have a meter. (an under $10 el-cheapo is just fine.)
You can't work on your bike without the manual.
You can't do electrical work without a meter.

I put some jumper cables to the battery and it was a no go. Same problem. Neutral light and oil light come on strong and bright but nothing else. Help

Also checked the fuse and all four plugs that come from the engine. Everything is fine. So I'm dumbfounded.

On 2004+, all connectors are under the right front part of the tank.
Most likely one of the connectors is disconnected. Remove the tank and check all wiring in that area.

The area you see here - probably a connector cane loose. Check the big ones and the single ones. Your wiring diagram will help sort things out if you use the color coded wiring diagram. Very easy to pull a connector when you removed and installed the engine.

In adidasguy's picture, see those two black cylinders near the top?  There are little spade connectors to each.  If they come disconnected then your spark plugs dont fire.  Check and make sure both of these are connected!

I swapped engines and shortly thereafter accidentally disconnected one after taking the tank off (or probably while putting it back on).  My bike ran on one cylinder for a ride, was REALLY weird.  I could see it making no noises if both are disconnected.

You say your sure you have power with that battery. Like the others said, check all your connectors.  There is a wire coming out of the back bottom left of the motor that I think is the starter motor.  Might check that.  I think I had to swap that out when I swapped a 98 engine into my 04.

Even if there is no spark, you should still hear the starter motor and the engine should turn over. There is something causing none of it to work. Make sure you are checking the real fuse, not the spare fuse. Check all connections under the seat and under the tank.
Also...make sure the kill switch is in the correct position 

+1 to the kill switch being on.

tend to forget things when you've been wrenching for hours on end

Since he says a couple indicators come on - fuse is OK.
No headlight: not the kill switch. Kill switch kills the engine, not the headlight.
My vote is going with the connectors under the tank. Both hand controls are there. Left hand controls the headlight. Right controls the kill switch.
Also as a check - what about the horn? No horn and left connector unplugged. We know the ignition is plugged in because a couple indicators do come on. So the key is turning on power.

Also look for the single barrel connectors. Those are easy to pull out and they can look connected when they need to be shoved in more.

I checked all those connections and everything seems to be good guys. I'm just at a loss here as to what would be the problem. It's really irritating me now.

Time to get out the wiring diagram and your meter.
You can follow the +12 everywhere and soon you'll find the break or loose connector.
The wiring diagram in color is available (and even on my photobucket page). Connect the black meter wire to battery ground and then turn on the bike and start following around the +12.
Its not hard. A wiring diagram is just like a map. Follow the lines and follow the wires.

my vote is a problem in the left hand controls. it has the Clutch switch and the headlight switch, both of those would cause the exact symptoms, try to bump start the thing and see what happens.

Quote from: crzydood17 on January 14, 2013, 10:11:04 PM
my vote is a problem in the left hand controls. it has the Clutch switch and the headlight switch, both of those would cause the exact symptoms, try to bump start the thing and see what happens.

That could take care of everything.
If the clutch lever got pulled out, also possible the clutch switch was broken. That can be shorted if broken.
Start button is routed through the clutch switch. Headlight routed through high/low switch so yep - most likely the left hand control is unplugged.

Does the horn work? How about blinkers?

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