Help! I'm going nuts - starter problem

[slamonte]

I have replaced old components with dyna green coils, dyna S, Duanes honda rectifer, and starter relay with BWD s5049. When I press my start button, nothing happens at the relay. I have measured 12 volts on the yellow/ green wire at the relay when the button is pressed. No voltage is going to the starter from the relay on the black wire when button is pushed. If I short across relay, the bike will turn over and start right up. Ihave replaced the starter relay with another new one with the exact same symptons. I'm going crazy trying to figure out why the bike won't start with the start button.

Hear is a diagram of how I have the wiring setup.

Any help appreciated...thanks GS Resources you guys are a Godsend

[psyguy]

i like your wiring "diagram"

the starter solenoid needs to be grounded

[hp1000s]

the starter solenoid needs to be grounded

Yes, ground it.

[Suzuki mad]

Have you cleaned the wires and connectors to the starter solinoid?

Suzuki mad

[slamonte]

I'm assuming the base plate of the starter solinoid is the grounding point. Is that correct?

Once I have all the connections correct and working, I will redo the diagram for future reference on this forum.

[slamonte]

All the connecters have been cleaned (or replaced) and ohmed out.

[rustybronco]

I'm assuming the base plate of the starter solinoid is the grounding point. Is that correct?

The solenoid p/n comes up as a ford starter solenoid, is that correct?
if so are there two small terminals? if it has two small terminals and two large posts, one of the small terminals is marked with a "s" that is the terminal you want the other "I" terminal being ignition by-pass.
yes the mounting bracket is ground.

[Lawhook]

Having the same issue

Keep us updated, I was out cleaning and replacing connection all morning and still getting nothing when the starter button is pushed...I got the suggestion to check the clutch handle switch, but you stated your getting proper voltage when you checked the green yellow, right...I'm going to attempt to replace the little contact holder in the clutch switch...But like I said please keep us updated...

[Suzuki mad]

You tested the right handle bar units circuit to see if that is working correctly? Yes. But changed the solenoid. Its not making the usual click sound so it would indicate either a lack of earth or a fault with the solenoid.

If you follow the red live feed from the soliniod do you have an inline fuse between that and the battery?

Suzuki mad

[seuadr]

Keep us updated, I was out cleaning and replacing connection all morning and still getting nothing when the starter button is pushed...I got the suggestion to check the clutch handle switch, but you stated your getting proper voltage when you checked the green yellow, right...I'm going to attempt to replace the little contact holder in the clutch switch...But like I said please keep us updated...

you can bypass that switch if you follow it back into the headlight and simply put a small clip of wire between the two plugs, then it's easily reversable, but you don't need to keep a hand free for the clutch.

[slamonte]

Your correct. The solenoid is for a ford. On one of the other post on this forum, someone mentioned this would work. It is definitely heavy duty and very well sealed.
I have it connected as you mentioned. The 's' is connected to the yellow/green wire and 'i' is not used. I will go out now and try to put a good ground on the baseplate.

[rustybronco]

Your correct. The solenoid is for a ford. On one of the other post on this forum, someone mentioned this would work. It is definitely heavy duty and very well sealed.
I have it connected as you mentioned. The 's' is connected to the yellow/green wire and 'i' is not used. I will go out now and try to put a good ground on the baseplate.

You have 12v on the yellow/green when the button is pushed, ground the solenoid and it will crank.
my-t big solenoid you are using there!

[Lawhook]

Not to interrupt

Hey seuadr, if I bypassed the switch and still nothing then its not the clutch switch?

[EZman]

I had the same thiong happen to me with a shadow. I grounde the metal and it worked fine.
I drilled out one of the rivets and replaced it with a small machine nut & bolt to make the connection for the connector and wire and just grounded the other end.
Ernie

[slamonte]

Thanks for everyones help!!! The ultimate fix was to ground the relay plate and make sure I had the starter wire in the 'S' and not the 'I' of the relay. Somehow in all my moving wires around I got it switched. It's all sorted out and I modified my entire grounding system along the way. I used a 4 post, 30 amp terminal (junction) connector to consolitate all my grounds and make shorter runs.

I ran engine ground (Chassis) and battery ground to the same terminal post and stated connect the other grounds as well. It cleaned up the wiring and made for shorter runs on many of the wires.

Here are some pictures:

http://s345.photobucket.com/albums/p385/slamonte2008/

Thanks again for everyones help! What a great forum.