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Starter or Starter Relay Problem

  • Thread starter Thread starter Astroman
  • Start date Start date
A

Astroman

Guest
My bike wouldnt start altough i have light and everything so i changed the starter relay by using one of a GS850 (on my GS1100 4v motor) Still nothing... Could be the starter? How can i find out if this is the problem before i buy a new one?

Bike doesnt make any sounds pretty much dead other than running lights, horn etc.....:(
 
When i connect the two terminals on the starter relay sparks fly but no starter sound..:rolleyes:
 
By pass the solenoid and apply 12 volts directly to the starter and see if it spins.
 
Astroman said:
When i connect the two terminals on the starter relay sparks fly but no starter sound..:rolleyes:
Click to expand...

If the relay is bad you should still be able to jump across it and spin the starter. I have a used starter in the one, (1981 GS1100) I am parting out.
 
The starter needs cleaned, rebuilt or replaced if you are bridging the solenoid posts and getting nothing.
When hitting the starter button you should be at least hearing the solenoid click. If not check the clutch interlock switch kill switch, connections to relay and ignition.
 
Got battery?

Also, is the ground cable hooked up firmly to the engine?
 
bwringer said:
Got battery?

Also, is the ground cable hooked up firmly to the engine?
Click to expand...


Yes battery is new i have strong lights. signals and everything...

The problem is somewehere between the battery and the starter...

How can i find if it's the starter clutch? Wouldnt the starter spins even with bad starter clutch...



Here is how everything started....


Me and a friend did a top end rebuild... Bike was starting and running before we take it apart..

After the rebuild we turn the key on and nothing happened... He did checked everything and found out that one of the wires that run from the ignition to the fuse box was cut somewhere inside the harness... so we did a small test with an external wire from the fuse box to the ignition and we got lights etc... He jumped the ignition Relay and we did hear the starter to try to start the bike .. then the second time sparks started flying... so did the 3 and 4 th time and then we thought might be the starter relay. I got a new starter relay but after i hooked up nothing happens... same like before sparks flying when i jump it...:(

What can it be? ****es me off that now that we put the motor togehter im not be able to start it and start riding the bike:mad::rolleyes:
 
Pretty much a bad ground ANYWHERE on the bike can cause this from my experience. Also, if your batt terms are corroded, or have a poor connection. You say you guys were having issues with a chopped fuse block or something? I would also start looking around there. A manual with a wiring diagram will be your best friend here.
 
Ok more to the story (excuse my English, is my Second Language)

After a bit more checking i found out that a couple wire connectors (noft factory my guess) where unhooked under the frame tube...

I did connect them and then when i switch the key to the On position the wire that goes from the Starter relay to the Starter became very hot and start smoking (mostly on the relay conection..) and makes a click from the solenoid my guess... bad starter? and why the wire gets hot and smoking...


What would be the problem?

ps: i used a 20 fuse on the main fusebox because i didnt have a 15 at this moment, cant be a problem right?

3136845071_f1f678b394_b.jpg



3136845725_9953b6f2a0_b.jpg




3137673190_5b074317e6_b.jpg
 
Last edited:
anyone? looks like all battery wires as well as the one goes to the starter get hot and start burning the plastic cover. the starter makes a click when i turn the ignition on ... nothing else happens...:o
 
Astroman said:
anyone? looks like all battery wires as well as the one goes to the starter get hot and start burning the plastic cover. the starter makes a click when i turn the ignition on ... nothing else happens...:o
Click to expand...

The solenoid should not 'click' when you turn the key alone on. Power only goes to the solenoid with the key on AND the starter button pushed.

If the solenoid is clicking when you turn the key on without the starter button being pushed then something is wired up incorrectly. If I'm reading this wrong and it is only clicking when you push the start button then the solenoid is trying to engage, but the starter is not turning. Can you turn the motor by hand?

If the solenoid is not clicking at all using the start button, then the most likely culprits would be the contacts in the RH switch block or the clutch interlock.
 
pontiacstogo said:
The solenoid should not 'click' when you turn the key alone on. Power only goes to the solenoid with the key on AND the starter button pushed.

If the solenoid is clicking when you turn the key on without the starter button being pushed then something is wired up incorrectly. If I'm reading this wrong and it is only clicking when you push the start button then the solenoid is trying to engage, but the starter is not turning. Can you turn the motor by hand?

If the solenoid is not clicking at all using the start button, then the most likely culprits would be the contacts in the RH switch block or the clutch interlock.
Click to expand...


the solenoid clicks when i connect one of the connections that's under the tank (see picture) and that happens when the ignition is On..


3139622106_be5b9fd9c1_b.jpg




When i connect one of the wires i have strong lights and everything but cant do nothing else.

When i connect the other one you hear the solenoid clicking (when turn the ignition on) and very dim lights... also wires get hot...

Wirring harness looks like is chopped to death.... very ****ty to be factory like that!!!! im about to sell this bike if i cant find what's the problem!
 
Last edited:
am I the only person to read this and know what exactly the problem is?

Astroman said:
Here is how everything started....


Me and a friend did a top end rebuild... Bike was starting and running before we take it apart..

After the rebuild we turn the key on and nothing happened.
Click to expand...


slight chance starter cover is smashed down and making contact with battery terminal on starter. odds are cams are way out of spec and at least one piston is smashed against valves that should be closed.

trying to save a little money has a funny way of getting real expensive! LOL :D
 
focus frenzy said:
am I the only person to read this and know what exactly the problem is?




slight chance starter cover is smashed down and making contact with battery terminal on starter. odds are cams are way out of spec and at least one piston is smashed against valves that should be closed.

trying to save a little money has a funny way of getting real expensive! LOL :D
Click to expand...

Starter cover is off

When we put it toghter and bridge the iginition relay the bike did turn over..

All valves where in Spec and cams where in the right positions acording to Manual.... from 2nd to 3th 20 links and right TDC
 
Last edited:
Astroman said:
the solenoid clicks when i connect one of the connections that's under the tank (see picture) and that happens when the ignition is On..


When i connect one of the wires i have strong lights and everything but cant do nothing else.

When i connect the other one you hear the solenoid clicking (when turn the ignition on) and very dim lights... also wires get hot...

Wirring harness looks like is chopped to death.... very ****ty to be factory like that!!!! im about to sell this bike if i cant find what's the problem!
Click to expand...


It looks like you have your wiring for the clutch interlock mixed up;

Katana2002.jpg

Katana2001.jpg


This bike is waiting to be stripped to the frame for a restore as soon as the weather warms up. I intalled a new Big Crank battery a couple of weeks back as I wanted to make sure it would at least turn over before I started working on it. I couldn't get it to crank until I cleaned the contacts on the RH switch AND bypassed the non-working clutch switch. It cranks over fine now.

The single yellow non-striped wire on the LH harness (for the blue plug) goes into the bullet receptacle with the two yellow/green wires on the RH harness (for the white plug). The clutch safety/interlock harness is on the LH side and also uses yellow/green wires (it's a separate harness that runs all the way from the LH switch). In my case, I have this plugged into itself to bypass the clutch switch altogether.

If you need any other photos let me know. Hopefully this helps.
 
Last edited:
Ok i found the start of all this mess...

We had to take the left side cover off to find TDC when i installed the cover back on i did a mistake i guess and one of the washers (i believe the one on the starter) slipped... So when we cracked the bike over to start this small washer went and stuck on the clutch starter with a result to stop moving the starter... battery was pussing hard to start and that was the reason wires where getting hot and smoking too...

Now i did bridge the starter straight to the battery but doest move so i guess i need to buy a starter of fix this one... ill try tomorrow on a car battery to see if spins with electricity (it does spin by hand)

3139836192_e36cb057b9_b.jpg


3139007459_25778c1b9c_b.jpg


Now i need to buy also a Clutch starter gear.. see cracked teeth?




3139836518_ed1ae1f2c7_b.jpg



3139843440_07e0cbdc6b_b.jpg


My guess would be one of #3 washers...
 
Well bike started and i rode it around the block a couple times what a difference in power

i have a small problem

1) the oil preassure light blings kinda like lose connection or something. Bike has oil and everything... :-k
 
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