gs 450 blowing fuse

[Guest]

I have just bought a GS 450 ( 1981? ) as a project.The bike is basically a wreck and needs a complete rebuild.My first mission is get it started to determine the condition of the engine. As this is my first attempt at restoring a GS I'm a real novice.My first problem is that when I press the start button the fuse blows immediately. Has anyone any suggestions. Thanks

[hillsy]

The 450's only had one fuse which makes it harder to diagnose than most other bikes that had 3 or 4.

Start by disconnecting ALL the ancillary components (lights, horn, headlight) and start from there.

It does sound like it is something in the starter circuit though - best also check the wiring from the battery to the starter and the wiring to the handlebar switch. Maybe PO simply wired it up wrong.

[stewart]

Thanks for that I'll give it a try. Electrics is like a black hole to me!

[Redman]

Welcome to GSR.

Think of what all items and circuits that has power before you push the starter button. No need to suspect any of those, fuse doesn't blow under that condition.

Now think of what else then gets power when the starter button is pushed, you should suspect these additional things.

And those things would be the
- clutch switch
and then when the clutch is pulled in, the
- starter solenoid
- starter motor (but no fuse on that big cable circuit)

Have you tried pushing the button without pulling in the clutch? if fuse blows then, the only additional thing in the circuit would be the starter button itself or the wiring to the clutch switch or the clutch switch itself.

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[stewart]

Thanks Redman, the fuse blows without me touching the clutch lever. I suspect the starter relay is at fault.I just need to work out how to test it, any thoughts?
Cheers Stewart

[Redman]

Thanks Redman, the fuse blows without me touching the clutch lever. I suspect the starter relay is at fault.I just need to work out how to test it, any thoughts?
Cheers Stewart

Stawart,

If suspect the starter relay is at fault, then disconnect it as a test to prove that is the problem. Disconnect the starter relay (little wire), push the button and if it doesn't blow the fuse like it did before then you know the problem was what you removed- the starter relay.
Since there is not a connector at the relay you might have to follow the wiring back up to .... ah, the headlight shell(?) to find a connector.
If the fuse still blows then problem isn't the relay, but something that is still in the circuit, like the clutch swtich, so dissconnect that, if fuse still blows then is just the starter button left in the circuit.


Oh, did you used to have to pull in clutch to run the starter?
If not, well then you don't have a clutch switch in the circuit, and the circuit is just the kill swtich, the starter button and the relay.
Dave

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[stewart]

Thanks again Redman, traced the fault to an incorrectly wired start button wire at the relay. Re soldered the wire onto the relay and started first go. Thanks for your help, i love this forum!
Cheers Stewart

[850 Combat]

That was smart. I was going to say that the starter circuit doesn't go to the starter, it goes to the solenoid (relay). Good for you. Have a photo?

[Redman]

............, traced the fault to an incorrectly wired start button wire at the relay. Re soldered the wire onto the relay and started first go. .....

Stewart,
Good!


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