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When I put my bike in the basement in November, it was idling a little bit rough, but otherwise running okay. I had an issue with the battery "boiling" and I ran the Stator Papers tests. It appeared to be overcharging and Duaneage was kind enough to supply me with a Honda RR. Over the winter, I took the carbs off and dipped them and adjusted the valves. I installed new positive and negative battery cables, a new cable to the starter and a new frame to engine ground wire, but other than installing the RR, did no electrical work. I bench synched the carbs and put things back together. The battery has been on a tender all winter and holds a charge at about 12.5 volts. A little weak but I didn't think it was a show stopper.
I put the key in and turned it on. The headlight came on as planned and the indicator lights are working. So far, so good. I pulled in the clutch, hit the starter button and nothing. Try the turn signals and horn and they work. Switch everything off and try again. Swear freely and try again in vain. Pull out the manual and start reading.
What I have done so far:
1) Tested the starter. It turns over when I jump the poles of the relay but grudgingly. It also grinds when I jump directly from the positive battery post. I have some advice on checking the brushes which I will follow, but it doesn't explain the immediate issue.
2) The manual suggests that the starter relay should be replaced because it doesn't click when I press the starter button. While making arrangements for a Suzuki relay, I also went to a lawn mower repair place this afternoon and pick up a universal 12 volt starter relay. It wasn't a long-term fix, but I figured that I could at least get the carbs properly synched, etc. for the weekend. I disconnected the positive battery cable, installed the relay, turned the key, pulled in the clutch, hit the starter button and still nothing. No click in the relay, same as before.
3) I tested for current in the wire that actuates the relay from the starter button. A little weak, but it tested at 9.1 volts when I pull in the clutch and hit the starter button. I have a very limited understanding of electrical systems, but logically, this seems right. I only get current when I hit the starter button with the clutch lever pulled in.
4) I pulled the headlight and checked the grounds in the headlight bucket. They test okay. I checked for resistance in the new wires I installed. They all test at .6 and I get a solid tone from the meter. The engine to frame ground tests at .6. The frame to negative post tests at .5 ohms.
5) I tested on both sides of the fuse block and they all show 11.3 plus going into the harness.
6) The wiring diagram shows a hot wire from the battery to the starter relay , a hot wire from the relay to the starter, a hot wire to the output terminal (I'm not sure what this is) and a yellow/green to the starter disconnect. The yellow/green is hot when I press the starter button and pull in the clutch.
7) I went back over the wiring diagram for the RR and I believe I have wired it correctly. I wouldn't have thought that it could account for this problem in any case, since the engine isn't running.
In any case, I'm out of ideas. I would be grateful for your advice on what to do next.
Thanks.
I put the key in and turned it on. The headlight came on as planned and the indicator lights are working. So far, so good. I pulled in the clutch, hit the starter button and nothing. Try the turn signals and horn and they work. Switch everything off and try again. Swear freely and try again in vain. Pull out the manual and start reading.
What I have done so far:
1) Tested the starter. It turns over when I jump the poles of the relay but grudgingly. It also grinds when I jump directly from the positive battery post. I have some advice on checking the brushes which I will follow, but it doesn't explain the immediate issue.
2) The manual suggests that the starter relay should be replaced because it doesn't click when I press the starter button. While making arrangements for a Suzuki relay, I also went to a lawn mower repair place this afternoon and pick up a universal 12 volt starter relay. It wasn't a long-term fix, but I figured that I could at least get the carbs properly synched, etc. for the weekend. I disconnected the positive battery cable, installed the relay, turned the key, pulled in the clutch, hit the starter button and still nothing. No click in the relay, same as before.
3) I tested for current in the wire that actuates the relay from the starter button. A little weak, but it tested at 9.1 volts when I pull in the clutch and hit the starter button. I have a very limited understanding of electrical systems, but logically, this seems right. I only get current when I hit the starter button with the clutch lever pulled in.
4) I pulled the headlight and checked the grounds in the headlight bucket. They test okay. I checked for resistance in the new wires I installed. They all test at .6 and I get a solid tone from the meter. The engine to frame ground tests at .6. The frame to negative post tests at .5 ohms.
5) I tested on both sides of the fuse block and they all show 11.3 plus going into the harness.
6) The wiring diagram shows a hot wire from the battery to the starter relay , a hot wire from the relay to the starter, a hot wire to the output terminal (I'm not sure what this is) and a yellow/green to the starter disconnect. The yellow/green is hot when I press the starter button and pull in the clutch.
7) I went back over the wiring diagram for the RR and I believe I have wired it correctly. I wouldn't have thought that it could account for this problem in any case, since the engine isn't running.
In any case, I'm out of ideas. I would be grateful for your advice on what to do next.
Thanks.
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