Insight will be appreciated:
After replacing the handlebar and reassembling all items mounted on it, bike will not start. No starter activity. Headlight and neutral green are all full intensity, battery is well charged, but nothing. The new handlebar is painted black - someone said there might be a need for grounding to the bar at the starter switch - but I do not see any metal within the switch that would normally make contact with the bar...
At wits end,
MaxB

Kill switch??



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Quote from: maxb on January 04, 2019, 04:57:30 PM
Insight will be appreciated:
After replacing the handlebar and reassembling all items mounted on it, bike will not start. No starter activity. Headlight and neutral green are all full intensity, battery is well charged, but nothing. The new handlebar is painted black - someone said there might be a need for grounding to the bar at the starter switch - but I do not see any metal within the switch that would normally make contact with the bar...
At wits end,
MaxB

Did you mess up the clutch safety switch? Its easy to break if you remove the clutch lever.

Thank's Bluesmudge and twocool...
I had replaced the entire lever complete assembly complete with new clutch safety switch - only one possible way to connect the wiring inside the headlight. So that can't be it.
Also, the kill switch seems fine inside and out, tried starting in both positions just in case, to no avail. Unless someone points out my (dumb) mistake, I'm going to cave in and truck this thing over to a mechanic... hate the idea.

By the looks of the wiring diagram there should be no need for the handlebar to be earthed to the frame (I replaced my handlebar a few years ago and did not have this issue)

If your headlight is good, it is likely the wiring harness / plug for the ignition is all good (and you wouldn't have touched that) my guess would be to try checking the wiring harness / plugs for the engine kill + front brake l/sw + starter button.  does the front brake sw light up the brake lamp?

Depending on your year, the orange / white cable could give you a no-start situation - the brake lamp would be an indication that this could be the issue before you start getting into wiring you haven't likely yet disturbed.

small bit of grease or something inside the female side of that plug could be the issue.

Have you tried bypassing the clutch switch completely? If you pull the cable off and insert a bit of wire into the ends of the plug to get a perfect connection this should rule it out.

Another theory could be the bike is not in neutral and the side stand switch is faulty meaning the bike won't start.

As far as I'm aware its only these 2 options + the kill-switch which can stop the bike from starting completely.