mirider Posted July 9, 2015 #1 Posted July 9, 2015 Decided to take a little ride this afternoon and got about a mile and a half from home when the bike went dead. Pulled over to side of road and tried to assess the problem - no power to ignition, lights, horn, etc. but did have power at the radio and GPS plugged into the DC jack in the fairing. Since I had an appointment in less than an hour, called my dealer who is only 3-4 miles away and he showed up with a trailer within 20 minutes or so and took the bike back to his shop. Hope to hear news tomorrow am but in the meantime, any thoughts on my problem ?? Sounds to me like a fuse issue but didn't want to tear into things on the side of a busy road.
Flyinfool Posted July 9, 2015 #3 Posted July 9, 2015 Kill switch should not take out horn and lights. I would certainly start at the fuse boxes.
Eck Posted July 9, 2015 #4 Posted July 9, 2015 I think your ignition switch went out on you. Mine did same thing..
mirider Posted July 9, 2015 Author #5 Posted July 9, 2015 Accidentally hit kill switch? Nope, first thing I checked. Had that happen at a stop light once and I learned a lesson.
mirider Posted July 9, 2015 Author #6 Posted July 9, 2015 I think your ignition switch went out on you. Mine did same thing.. Thanks for the thought Eck, I'm sure dealer will check that.
Eck Posted July 9, 2015 #7 Posted July 9, 2015 Thanks for the thought Eck, I'm sure dealer will check that. You might want to consider by-passing the ignition switch when you get it back even if this is not the root cause. They are known to fail all the time.
cowpuc Posted July 9, 2015 #8 Posted July 9, 2015 You might want to consider by-passing the ignition switch when you get it back even if this is not the root cause. They are known to fail all the time. Tell ya one thing for sure,, THAT is a very good suggestion considering the fact that when things happen they always seem to happen at the most inappropriate time. I had the same thing happening years ago with our 79 Chevy Starcraft Conversion van and, after happening twice while traveling long distance in it, wife and little kids headed west, I took the second switch apart and found it DEFINITLY unworthy of the amp draw it was expected to take.. I did as I think Eck is suggesting and put a bypass on the switch with a "hidden" button and switch under the dash.. Wasnt long and Tip had learned to used that bypass fluently!! Another thought concerning the matter, I wonder how many folks who have had ignition switch problems on their 2nd Gens carry a lot of extra stuff on their key chains - not good - extra weight/movement on that switch may be inviting trouble. Just a thought.. Hey MiRider, along with the switch and the fuse thoughts,,, could also be one of the terminals wasnt "snapped" shut or pressed on all the way and it just wiggled loose.. Maybe pinched wires (hope not). Please let us know what they find my friend!!! Puc
Flyinfool Posted July 9, 2015 #9 Posted July 9, 2015 The ignition bypass on the 2nd gens is adding a relay to carry the current and the ignition switch is only switching the relay coil power. This way it still works just like normal.
cowpuc Posted July 9, 2015 #10 Posted July 9, 2015 The ignition bypass on the 2nd gens is adding a relay to carry the current and the ignition switch is only switching the relay coil power. This way it still works just like normal. Got cha Fool!! Thanks for heading that off my friend!!! Sounds like a REALLY REALLY GREAT IDEA!!! Guy could probably use a relay from an Autoparts store?? Or would one have to chase down something special? Wonder if one of our member vendors sells a plug and play kit for accomplishing the task (knowing you, ya probably got one in your pocket )
mirider Posted July 10, 2015 Author #11 Posted July 10, 2015 Actually have a "plug and play" relay installed, bought it on this site....[emoji106]🏻
djh3 Posted July 10, 2015 #12 Posted July 10, 2015 I make the by pass relay kit. I make them in a standard whick simply installs and helps save the switch. Or I can make a keyless for a complete by pass if needed. I am also working on sourcing a switch so I could make a complete kit for someone should the OEM switch fail. All of the kits are plug and play. PM if need more info.
mirider Posted July 10, 2015 Author #13 Posted July 10, 2015 Puc - Don't have a keychain, just use a lonesome old key in the ignition.
mirider Posted July 10, 2015 Author #14 Posted July 10, 2015 I make the by pass relay kit. I make them in a standard whick simply installs and helps save the switch. . Actually, yours is the one I bought and installed.
Great White Posted July 10, 2015 #15 Posted July 10, 2015 Main fuse will kill everything on the bike all at once when it blows....
cowpuc Posted July 10, 2015 #16 Posted July 10, 2015 Now I wonder if the relay bypass may have failed,, far better it than a key switch if it did..... Be interesting what the shop finds MiRider..
Eck Posted July 10, 2015 #18 Posted July 10, 2015 Main fuse will kill everything on the bike all at once when it blows.... Couldn't be the main fuse. He mentioned that he did have power at the radio and GPS:stickpoke:
djh3 Posted July 10, 2015 #19 Posted July 10, 2015 I supose it could be a failed relay. But in the close to 100 of these I think I have built I have got 1 bad relay. And I found that on a bench check prior to shipment. Also I think if if relay goes bad it would act just like key was off because now power would cross switch.
Great White Posted July 10, 2015 #20 Posted July 10, 2015 Couldn't be the main fuse. He mentioned that he did have power at the radio and GPS:stickpoke: If the 2nd gen is like the first gen, then the DC port is wired direct to battery. Main fuse can blow and not effect it. If 2nd gen is different, carry on....
mirider Posted July 11, 2015 Author #21 Posted July 11, 2015 Unfortunately, dealer didn't have chance to tear into things yet, hope to hear something Monday. Passed all suggestions on to him, thanks to all [emoji106]🏻. Stay tuned for further developments [emoji102].
mirider Posted July 14, 2015 Author #22 Posted July 14, 2015 Update - Picked up bike from dealer today and it appears the cure was worse than the malady. Turns out the ignition bypass unit I installed this spring shorted out and melted the plug at the red wire connection, pictures attached. Have no idea what caused this, been running with the unit installed for some time but it's obvious this was the problem. Dealer removed unit, plugged the factory connectors back in and power immediately was restored to the bike. He tested the switch and battery also and turns out I needed a new battery but the ignition switch is fine at this point. Some days it doesn't pay to get up in the morning.
djh3 Posted July 15, 2015 #23 Posted July 15, 2015 Shoot me a PM. I will replace the unit for you. I sure would like to know what the heck went on there. How long has it been installed? I'll make it right. In the probably over 100 units I have made I can say this is the first one that someone has had a problem like this. Almost looks like overheat issue. Maybe a bad connection at plug? Extremely sorry for your troubles.
mirider Posted July 15, 2015 Author #24 Posted July 15, 2015 djh3 - Thanks for the response and offer. Sent you an email.....
djh3 Posted July 15, 2015 #25 Posted July 15, 2015 Well I guess you can get something bad every once in awhile. I looked at my records since I started keeping them. I made about 10 before I did. I have made over 100 of these and its the first I have had fail. Like we discussed, when I get the old one back I'll look it over to see if I can maybe figure out how it went bad. I'll get a new one out to you soon.
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