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Electrical Problem

  • Guppy
    Guppy
    16 years ago

    BIKE DOESN’T START – ELECTRICAL
    73/74 XLC
     

     

    What I have done to test the Solenoid, Relay and Starter: (I'm hoping this hyp link will work or this may not make sense).   BIKE DOESN’T START – ELECTRICAL

    Relay: Fig 3
    1.       With everything connected, the start button pushed would only cause a clicking in the Relay.
     
    2.       On the Relay I placed the test light on the wire from the start button and pressed the button, it light up.
     
    3.       Still on the Relay, I then put the test light on the terminal marked “to Solenoid” and pushed the start button, it light up.

    Starter Solenoid: Fig 2
     
    1.       I placed the test light on the terminal marked “From Relay Start Button” and pushed the start button, it light up. This confirmed the Relay was good.
     
    2.       I placed the test light on the terminal marked “to Starter” and pushed the start button, No light ????
    Starter: Fig 3
    1.       Still with everything connected, I connected a wire form the terminal marked “from Relay Start Button” (Fig 2) to terminal marked “to Starter” (Fig 2) and pushed the start Button, the starter engaged and turned over the engine.
     
    2.       I then went from the main Bat + terminal to the terminal marked “to Starter” and it engaged and turned over (no need to push the start button here).
     
    3.       I then disconnected the wire marked “To Starter” (Fig2) and placed the test light on that terminal and pushed the start button, (WTF) it light up.
     
    4.       I then disconnected the terminal on the Starter (Fig 3) thinking the wire might be earthing out and replaced it with another one and tried to start it but again only the ticking of the relay could be heard.
     
    Conclusion
    1.       This is where you come in.............. I think “and I am no electrician” that the starter motor bushes could be worn ?????? But how could this be if it turns over if the wire is connected direct to the Bat + ???
     
    2.       I think I have eliminated the Relay and the Solenoid (which are both new) because current is getting through, until the starter motor is connected.
    Help
    1.       Any assistance/thoughts would be appreciated and investigated
  • Guppy
    Guppy
    16 years ago

     Well I have found the problem, after removing the solenoid I had a look at the operation of the plunger.  This is where the problem lies, I gave the plunger a push with my finger only to see it go right back into the housing and sit against the inerside of the primary cover.  So I removed the cover and the Plunger, boot and all fell out.

    From the Pic below item 25, the shifter lever has snapped.

    The snaped shifter lever

    Where it is supposed to be.

     

  • Guppy
    Guppy
    16 years ago
    Thanks all, she's up and running again.
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