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Bloo Moderator
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Discussion Starter #1
Maybe we should have a contest type Forum for this stuff its fun to play around with, I even got my lady and son involved by showing them the Electrical Starter System Schematic only and described the problem. :mrgreen:

As some of you know I have 3 Gen 1 Bikes now so future troubleshooting it may help with part swap for easy troubleshooting but not needed in this case…..take your best guess. :thumbsup:

Symptom: Bike starts as soon as you turn the Ignition Key to ON Position but use to work for weeks before the failure and restore.

History: Bike is a 2004 Green is a wrecked Repo and restored by me maybe only 4-8k miles on the OD no rain damage…previous damage was all front end wiring at the headlight, starter clutch problems, and minor electrical problems for the headlight wiring at that fuse box. It also may have sat without being started for many years maybe 8yrs but that is just a guess.:dontknow:

:popcorn: Bloo
 

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stuck/broken starter button and or pinched starter wire grounding out. That's a basic 2 wire loop.
 

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The starter circuit is a three stage relay and the 1st stage is easy to damage. The 1st stage is in the relay box and is coupled with a stator wire to turn the headlights on when the starter button is released. This is 3 relays in series, low power, medium power and then the high power that actually engages the starter. I chased this circuit a lot when my son's gen2 had the starter running intermittently after a stator and r/r failure. If the starter actuates while the engine is running and the battery is charging, too much current is drawn through the r/r regulator and it usually blows and could also burn the stator. The short story is: Replace the relay box with new. The used ones on ebay are a crapshoot because many are bad already. With 3 gen1s you could try a swap out with one of your other bikes to test before buying one. HTH :biggrin:
 

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Bloo Moderator
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23,742 Posts
Discussion Starter #4
stuck/broken starter button and or pinched starter wire grounding out. That's a basic 2 wire loop.
The starter circuit is a three stage relay and the 1st stage is easy to damage. The 1st stage is in the relay box and is coupled with a stator wire to turn the headlights on when the starter button is released. This is 3 relays in series, low power, medium power and then the high power that actually engages the starter. I chased this circuit a lot when my son's gen2 had the starter running intermittently after a stator and r/r failure. If the starter actuates while the engine is running and the battery is charging, too much current is drawn through the r/r regulator and it usually blows and could also burn the stator. The short story is: Replace the relay box with new. The used ones on ebay are a crapshoot because many are bad already. With 3 gen1s you could try a swap out with one of your other bikes to test before buying one. HTH :biggrin:
Well been busy this weekend sorry for the late response but I think you both maybe right direction.....I think I unstuck the relay by hitting the starter button after the bike started then sprayed Lubricant in the left Ignition handle bar housing...either way it fixed the problem for now.... but still will investigate it may come back....the key here is there was enough current to open a relay but not enough to keep the Starter Motor operating after start-up....I will monitor and report back just wanted some to see if you send a problem to your dealer expect to have parts replaced first that don't need replacing. :wink: ....learn your bike and the Electronics first can save you alot of trouble. :thumbsup:

Bloo
 
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