I hate Wiring....

[nzemke]

So I have been striving to get this monster up and running for a good long while. I had an issue before where the bike would just sit there and do nothing when you hit the starter button. Last time it ended up being that the brain had fried. So you can imagine that with the return of this issue I have attempted to smell every inch of the starter unit and haven't found a single hint of fried electrical. I have tested the wires running from the Right handle at the switch to the fuse as well as the resistance through the switch verifying that it works. And that it is grounding properly from the fuse through the handle bars when the switch is turned to on. I know where the cable is coming out of the on push button but I have no clue where this is running to? Where on the bike does this go? For me a picture would mean a million words! I just need to know where it is going to. The cable is Blue/Yellow.

Thank you ahead of time!!!

[James England]

Are you saying the TCI fried last time? That in itself wouldn't stop the starter motor from working.

The starter button wire activates the starter solenoid on the right of the bike under the side panel.

I just did a little tutorial about how to service the starter motor itself

Have you checked that the solenoid us working?

[nzemke]

All good things to know! Last time I took apart the TCI unit and a corner of it was completely black and smelled awful. Didn't know that this would be a direct result of another issue. I can now test the wiring and see whats going on with that part. If all else fails I have a spare one I can drop on there Thank you so much! Will let you know how this turns out.

[motoman]

ALL grounding locations need not looked at, but removed, cleaned both surfaces and re-attached. Goes for ALL electrical plug-ins.......don't skip any just cause they may 'look' okay. Also, the STOP switch completes the starting/running circuit. That needs to be reomeved, taken apart and ALL pieces soaked in EvaporRust and cleaned. The starter itself is HIGHLY unlikely the issue. The fuse panel, if original needs replaced with a blade fuse holder panel. T.C. sells those for minimal cost. That'll get you STARTED in the right direction.

[CaptonZap]

When you had the cover off of the TCI, with the plug in's at the bottom, was the burnt place on the lower right corner of the board?
If so, it might be the diode that by passes the current for the starting voltage, and if there was a short in that line, it would burn out the diode.
The red/ yellow trace feeds battery voltage from the start solenoid to the diode, through it to the coils via the white / red tracer, bypassing the coil resister.
If that was the problem, let me know and I will attempt to give you a way to test the wires.
If you are going to throw the old TCI away, I would be happy to give you postage and my address and have you throw it my way. It might be repairable.
Let me know,
Thanks, CZ

[nzemke]

Sadly I already tossed it Sorry. But that does sound about right.

I just replaced the starter solenoid and I'm not sure if this is the same as the first one but I accidently touched across the two posts and it turned over. So I excitedly tried the starter button and nothing happened So I threw the multi-meter on and tested and the resistance drops to the solenoid when I hit the start button. but with the key turned and linking the two posts it turns over. Is there a way to test the solenoid or does it sound like there is something else going on?

[nzemke]

ALL grounding locations need not looked at, but removed, cleaned both surfaces and re-attached. Goes for ALL electrical plug-ins.......don't skip any just cause they may 'look' okay. Also, the STOP switch completes the starting/running circuit. That needs to be reomeved, taken apart and ALL pieces soaked in EvaporRust and cleaned. The starter itself is HIGHLY unlikely the issue. The fuse panel, if original needs replaced with a blade fuse holder panel. T.C. sells those for minimal cost. That'll get you STARTED in the right direction.

Already took apart and completely cleaned the kill switch and replaced parts from the two in order to make the perfect one Sounds like I need to run through the electrical connections one more time.

[BA80]

The TCI won't have a thing to do with the starter cranking the engine, it controls the firing of the spark plugs.

[nzemke]

The TCI won't have a thing to do with the starter cranking the engine, it controls the firing of the spark plugs.

Yeah James England covered that one

Another person on another forum I saw said to check the red wire for voltage...in this case there was no voltage going through that part. Is that accurate? If so without the voltage am I back to the switch??

[BA80]

If you're speaking of the red wire with a white strip that goes to the kill switch, yes it should have power. There should be 2 of those wires there and with the kill switch in the run position there should be power to both.

[nzemke]

sigh.....so how much is that new fuse box...because that is where the issue is at....

[motoman]

sigh.....so how much is that new fuse box...because that is where the issue is at....

bingo.......

......just enough to get cha' back up and runnin'.............imagine he'll chime in or send you a PM.

[nzemke]

from TopCatGr58?

[nzemke]

So the saga continues....So since I am broke till middle of the month I decided to see if I could just clean the contacts and get her to work till I can afford the new part...So I took the dremel to it and cleaned up the contact points so they make contact again. Only now it blows the ignition fuse the second I turn the kill switch to on. I swapped the starter solenoid back for the one I took off yesterday in hopes that I was just seeing a bad one but getting the same thing....

Anyone know what this might be....I'm confused as all hell

[BA80]

Unplug the ignition resistor and see if the fuse blows.