Dumb mistake putting the loom back in.

[thatshitcray]

Loom was out, put it back in and it wouldn't start. I knew the battery would be flat so jumpstarted it.. figured out afterwards that a negative from the starter to the battery was missing.

So, what have I ruined?

I can jump start it but it can't ride for more than 1km. Upon playing with the electrics today, when trying to start I lose all power. No headlights or anything when on. So, is the starter relay the culprit for this? And not running for more than 1km, could that be the starter or have I also burnt the stator?

[The Buddha]

How did you jump start it with out negative from starter to battery Which I am not even sure exists.
The frame/motor etc are negative, the negative cable is bolted to the engine case. The starter grounds to the case simply by virtue of being bolted in there.
Almost every thing on this planet that has an electrical system negative of battery is bolted to engine and frame.
Some accessories like horn etc in some bikes - like the GS work on the button connecting + and - at the button, but some others like 70's and 80's hondas worked on connecting the + to ground at the button. As in the + went to the horn, and on the other pin returned to the horn button. Press it and it gets grounded completing the + to horn, to other pin on horn to handlebar (ground).

I dont know the answer to your question, and I open up a receiver and laugh at it before fixing it.
But exactly what did you not connect and how did you jump it ?

Cool.
Buddha.

[thatshitcray]

Hahaha.. Yeah man, I'm not sure, but it was the negative from the relay missing.. it doesn't make sense to me either, I must be mistaken about when it started and when I found the negative not connected. Either way, when it did start it wouldn't stay on without the jumper battery pack connected, so that seems like symptoms of the stator to me.

This issue has been such a headache I'm replacing the starter and the stator. I might test both and comment what was broken incase somebody else makes the same mistake.

[SK Racing]

It sounds like the battery isn't charging and you're running out of battery juice after 1km. Have you connected the 3 alternator wires to the R/R?

[thatshitcray]

C'mon SK, I made a dumb error but not THAT dumb. Could it have been the spark plug polarity reversed!? It sounds like it could have been.. was revving high because I thought it was a battery issue and wanted to ensure I was giving it charge but it kept failing! On the push home I got it over a bridge in first, which also sounds like it was possibly this dumb error.

Soooo... Which plugs go where on the spark plug coils? One polarity is a right angle plug the other is a straight.

[The Buddha]

A fully charged battery with a completely dead alternator will get you ~14 miles of riding with 1 start. A bit more than 20 if you're not running any lights. Racers routinely do that. So 1 km is a bit dismal, you may have started out with a nearly dead battery to start with. You cant diagnose charging problems without a fully charged and known healthy battery.
Cool.
Buddha.

[thatshitcray]

What the F is this squeeling noise!!

I'm going crazy! This thing has been off the road all this time for more aesthetic mods and since I never really confirmed what this was I replaced the starter relay, the stator and the controller. Originally I had tested with two regulators so that's pretty much ruled that out.

When I tried to start earlier I was just getting a clicking sound, so I charged the battery. Now so get a single click on a full battery. With a jumper pack plugged in I get the squeeling noise.

What do I need? Is this fixable? Where do I look and test next?
Always appreciate the assistance, Ty.

[Armandorf]

What the F is this squeeling noise!!

Which noise?

I'm going crazy! This thing has been off the road all this time for more aesthetic mods and since I never really confirmed what this was I replaced the starter relay, the stator and the controller. Originally I had tested with two regulators so that's pretty much ruled that out.

What do you mean by "controller" , the handlebar switch?

you have
1 charging for one side = magneto + stator + regulator/rectifier + battery

2 starter system = 
bendix(also called starter clutch ,don't remember the name now, behind the clutch basket it is , this has the ability to engage with the crankshaft when the starter gear (could be broke? dont think so) spins along with the starter motor
+ starter motor + starter relay + handle bar switch + sidestand switch and relay

3 ignition = pickup/signal generator + cdi/ecu/igniter/black box + coils + sparkplugs , also all this is interrupted by the kill switch

When I tried to start earlier I was just getting a clicking sound, so I charged the battery. Now so get a single click on a full battery. With a jumper pack plugged in I get the squeeling noise.

Only one click and then nothing?
Do you have a multimeter? Did you take some measurements?
1st clicking sound is the starter relay alone, it is supossed to connect the starter to the battery. Does the starter spins?
You can jump the two big wires on the relay, and the starter motor should spin.
That is what the relay really does, if it is working, the energized coil through the starter button in your thumb in the right handlebar switch  triggers it.

What do I need? Is this fixable? Where do I look and test next?

Stop throwing parts at it and diagnose the problem.  Look  up for the wiring diagram.

Always appreciate the assistance, Ty.

As many others here, im happy to help and learn in the proccess.

[thatshitcray]

Which noise?

A squeak or squeal coming from the starter relay.

What do you mean by "controller"

The cdi ignition control.

broke? dont think so) spins along with the starter motor

I'll take this off and look into it but nothing is spinning, no other sound is coming from the bike except the screaming dead mause in the solenoid.

Only one click and then nothing?

No, clicking. Now the battery is charged I get squealing. When I tested last night at almost full battery I would get one click and a squeal but with the jumper connected and now with full battery I just get the squeal.

You can jump the two big wires on the relay, and the starter motor should spin.

Great, I'll test that.

energized coil through the starter button in your thumb in the right handlebar switch  triggers it.

I've done significant work to the electrics, and the bar controls were part of that, what do you mean energised coil.. I thought this was just a switch, what other function was it!?

Do you have a multimeter? Did you take some measurements?

I measured the volts at 11.5 drop past 7 when it was clicking. This suggested battery to me and now I don't know.
--------------
I'll do some further troubleshooting now but if you have any further suggestions or think of any readings from the multi that may assist that would be great. I'm worried about having to take apart the front electrics but I only have 3 things to look at before I have to
1. Engine not seized test
2. Starter motor hooked up directly
3. Starter relay hooked up directly
(Maybe 4. Starter gearing, but it doesn't look that way to me)

Cheers mate.

[thatshitcray]

Stop throwing parts at it and diagnose the problem.  Look  up for the wiring diagram.

This is good advice.. Thank you mate. I just wanted it to run when the mods were done. I've resolved it, and even after 18months off the road she runs beautifully. From the very beginning it might have been this failing intermittently. And it must have been the only thing I had not tested, I know the wiring of this thing like the back of my hand but I had not tested this one thing because the F k N connector is garbage. And that's it, many of you would know which part this is, and the amount of people, even me now, that this part gets, the whole time thinking it couldn't be so simple.

Test. Everything.

[Armandorf]

1. Engine not seized test
spin it by hand, you have to remove pickup signal generator cover

2. Starter motor hooked up directly

3. Starter relay hooked up directly
(Maybe 4. Starter gearing, but it doesn't look that way to me)


Perfect.


well, it seems to me that the engine is locked somehow and that would explain why when the starter motor tries to run the voltage goes down so much. Beware or you can cook the starter. or your battery is dying or something is draining it.

Again, a multimeter is you best friend here.