Good evening gentlemen. Hopefully someone can point me in the right direction. Bike was running great yesterday and today won't start. Turn on the ignition and the headlights on (high and low), parking light, turn, low oil pressure, turn signals... everything. Flip the kill switch to run hit the start and nothing. Not even a click on the start relay. Looked at everything I could possibly think of. Headlight relay, side stand switch, pulled the start relay checked it, checked the ignition button, che ked the wiring in the bucket, checked the coils, checked the pick-up coil and all the fuses. Everything I've checked was in spec. Even put a brand new battery in. Nothing is working. Hopefully someone can help.
check the main ground. its at the back of the motor case near the rectifier.
Update: jumped across the start relay and she fired up. However, there's no voltage when checking the checking across the blade to the lug when pressing the ignition button. Also, when I jumped it I didn't see the headlight cutout. Is it more likely that it's the headlight cutout relay?
Finally got it figured out and learned way more about the ignition circuit that I ever care to know. To top it off it was one of the easiest fixes too..... it was very minor corrosion on the ignition button contacts. Took it completely apart and it looked fine but decided to lightly scrape it with my pocket knife, put it back together and she fired right up. Man I hate electrical gremlins.
I try (if I remember) to spray my bike with CRC spray when I park it for the winter
https://www.crcindustries.com/contact-cleaner-protectant-10-wt-oz/ Spray in and around the handle bar controls, behind the key switch, connections, fuse box etc...
Glad you found the problem. Yea, electrical bugs suck
I have had the same problem 3 times now and everytime it was the starter (headlamp) relay. Can't for the life of me figure out why it keeps going bad but it does.
maybe heat related for your relay? unrelated to this but I have a BCS rototiller which is Italian made, always gave me trouble starting, always a dead battery, slow starting etc. It had an electronic relay/solenoid, I picked up a Ford style solenoid and never gives me a problem since. Use it in the spring, park it,use it in the fall and park it again till next spring. NO dead battery, NO slow lazy starting, just tickle it, little choke, bam its running.
I had one go bad when we were at the Arizona rally. I stopped by an Advance auto parts store and a guy named Harley let me wander around the shelves and with his help we found one that got me home. Unfortunately that was the relay that went out one dark night on Blood mountain and left me without a headlight.. I had to follow Moes tailight down the mountain.