redrider to the rescue again

[j_berg]

Thanks again redrider.After 5 hrs of searching and we found the problem wire.Now the bike starts when pushing the start button instead of starting when you turn the key.And the air horn works great too.thanks for spending your holiday in my little messy garage.

[RedRider]

Jeff, It was a pleasure. I learned a lot about how this bike is wired.

 

For a synopsis of the problem and the solution -

 

J_berg was installing a Wolo horn and something happened such that the bike would start whenever the key was turned to 'run' (if the kill switch was 'on'). We started at the back and tested the starter control relay. It was good. Then we tested the starter relay, it was good. Then took apart the start button. It appeared the spring had fallen over and was making permanent contact. Thought we had it solved. Nope.

 

Then we started tracing the wires from the starter button. It seemed to have a permanent connection to ground. Took the tank off and removed the wiring cover bracket. Checked the main harness connector next to the ignition. The blue/white wire was fine from the connector to the starter control relay.

 

Took off the fairing front. Started disconnecting main harness connectors until we traced it between the main lower harness connector and the throttle wiring connector. OK, we have it surrounded. Started taking off the electrical tape on the main harness and found.... the blue/white wire goes TWO places!!!

 

Traced the other location to the main radio control box. There is apparently an input from the starter switch that turns the radio sound off while starting the bike. Sure enough, the connecting wire to the radio control box was grounded withing the control box. We disconnected the radio control box and everything worked (except the radio, of course).

 

It appears during some earlier modifications, something with the wiring got crossed, grounded, or something and caused a malfunction within the radio control box.

 

Put everything back together and it was still working. No parts were left over. Oh yeah, we also installed the horn and it is working.

 

Jeff now has a running bike without any radio. Will likely need a replacement radio control - or an Ipod with ear buds .

 

It was a great day to wrench and help someone get back on the road. Good times were eventually had by all. Jeff was getting a little frustrated and worried (so was I, however, tried not to show it).

 

Anytime you need help, let me know.

 

I'll let you know how the venison turns out. Wife already had some things thawed out for dinner. Will likely fire the steaks next weekend.

 

RR

[j_berg]

I dug into it a little further tonight and found the radio still works when I plug in my head set but I had to crank the volume and then could still barely here it.

[Flyinfool]

Sounds like a fun one to figure out.

 

Mmmmmmm........

Dead deer steak..........