Wtf??

[jte8969]

ok, this is what I have so far. I took apart the right switch and cleaned everything as best as I could. Then I started her up and tugged on some pick up wires. no change, so I suppose I can rule that out. I think I might need a new start button. It doesnt always start right when I hit the button, almost like its not making contact. This is where I stand right now, any idea's on where to go next??

[Incubus]

What did you clean up in the right switch? Did you disassemble the starter button and clean the contact? Did you remove and disassemble the kill switch and polish up the little copper plate and the two contacts?

Those are the two points I can think of that interconnect with intermittent starting and stopping suddenly without apparent cause. The R/W wire that runs through the kill switch powers both the solenoid and the coils. If it is corroded you would lose power to both. If is it sorta corroded you could lose power randomly as contact is made and lost.

Patrick

[jte8969]

I did take apart the kill switch and took some fine sand paper to the copper. the switch is fine. As far as the start button. I didnt get that as well as I wanted. I sprayed some cleaner in there but could really get it apart like I wanted. I'll have to try to get more time for that. Is there an easy way to get that apart?? The wire is soldered so its not easy gettin it out where i can really clean

[DGXSER]

The start button consist of a plunger you see external to the switch, inside it is a metal plug, the back side is what connects to the plate the wire is connected to, with a spring in between to transfer power from the plug/plunger to the frame of the switch. The black wire or ground connects to the frame so when the switch is pushed in it completes the circuit. So, a dirty or rusty spring, button, or frame can hurt the performance.

The frame makes a U shape and wraps the plate the wire is connected to. The bottom part sits behind a lip in the switch housing so it will not simply push back with the screw removed. Sometimes the easy way os to pry the top part of that U up to pull the plate with the wire on it out of the way. Then get the rest out of the frame and then pull the frame up and out.

So it sounds like it runs now correct? Will it quit suddenly again? Who knows till you try, so take short trips at first.

[Incubus]

Remove the screw that hold the starter button assembly to the switch housing. work the entire button housing out. Two tabs, top and bottom, hold the starter button housing together. Compress the spring a little and pry the housing from the tabs and button housing comes apart. Be careful as the spring and the housing will then be loose and will quickly spring free and will not be found until after you have already bought replacements. Polish up all points of contact, including the spots where the spring touches and the housing itself, as ground is made from button to button housing to spring to switch case to handlebar.

Patrick

[DGXSER]

Hey Patrick,

Not sure if it was in 80 or 81, but they added a ground wire to the harness for the starter so it should not go through the handlebars anymore. Never owned one, but I believe the older models did not have the black ground wire to that switch.

[Incubus]

My '79 has that ground wire, DGXSER, but I believe it is just additional to the original design. The starter button on my '79 works whether that wire is connected or not. I believe it was planned redundancy to improve the ground.

Of course, I could be wrong.

Regardless, if he polishes everything up the button is going to work, wherever the ground comes from.

Patrick

[DGXSER]

The cleaning and or polishing will be the cure if the switch is the issue, you are correct.

Sometimes I hate being such a detail oriented engi-nerd, never helps my typing though. My guess is they had more than a few issues with the grounding through the bars method, so they threw that wire in but did not change the original ground path as it could only help. I was just thinking that the handlebar to switch contact is not required is all. I'll have to test that theory on Banshee later today perhaps.

[DGXSER]

I was just thinking that the handlebar to switch contact is not required is all. I'll have to test that theory on Banshee later today perhaps.

Tested and confirmed, at least on an 81 model. The handlebar is no longer the ground, that black wire does it. Switch hanging off the bar, no contact, only wires for connection, hit the starter and she cranks and fires up.

[Crazcnuk]

I just went through this, too. ALl of a sudden, no crank. Took the switch housing off my other bike, the one I have been riding for the last 4 years, with no problems, and nothing.

Went through everything else, but the issue was power to the one red/white wire, but not to the other through the kill switch.

Cleaned it, now it works fine.

BTW this is the 78, and it had the ground wire, but it was all fried. It is now working w/o it.

I know the switch assy had been changed, though as it has no on/off for the headlight.

My 80G did not have the ground wire, and my 79 special has a completely different plug.