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Starting/ Starter Issue

Joined Mar 2013
3K Posts | 161+
Naples, IT
Here we go again...

Just got Francesca back together after sourcing new vertical downpipe and a bunch of other loose ends. One of the updates was an upgraded starter and grounding wire kit. Had a lot of trouble getting the stupid nut off the starter lead wire to replace it. When I went to mount the new starter lead, found the wire post was moving around a bit in the starter case. Like, the post for the starter lead had play. I got it to bite as I secured the new lead but it didn't sit well with me. Wouldn't be able to test till I got the tank and all the electronics back in.

Got it all back together today and flicked the starter. Got an electrical *pop* from the starter solenoid box (circled). No movement from starter and dash reset. When I tried a 2nd time, same *pop* and then the dash screen booted to "M.A.E." title screen with software and "PTA" version info. Disconnected battery, which was fully charged, checked all connections, inspected solenoid box in picture. No blown fuses, either. Same results on next attempt.

If someone says it's the starter, I'm probably gonna dowse in kerosene and toss a match. I am not in the right head space to remove half the engine to pull the starter. Not sure if I can remove the starter shell while it's installed. Really hoping for a brilliant quick fix from someone smarter than me.
 

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Commiserations gatdammit. The obvious possibility is a dead short to the case of the starter motor, due to the terminal coming loose and twisting. Looking at both my starter motors, old and new, the terminal post seems to be within the end cap, so you'd be fighting the internal connections to try to remove it.

Have you tried loosening the outer nut, taking the new lead off and trying to find a sweeter spot for the terminal post? There's no guarantee that the connector inside hasn't twisted permanently, of course, but if you bias the post clockwise, that might undo the damage you inadvertently caused trying to loosen the nut.

Good luck, but if that fails, you know what you have to do...

Nick
 
Any chance it could be the solenoid box circled? I checked the fuses inside but didn't reset the leads. Any suggestions on how to go about testing this circuit and the starter with a meter?
 
You can bridge the big contacts of the solenoid to send power direct to the starter to see if it will spin then, but be prepared for sparks! I don't know if that could have consequences for the electrical system but I don't see why it should. Doing that will take the coil of the solenoid out of the circuit temporarily. Since you know the starter terminal suffered in your recent work, it may be that your solenoid is now toast, but the basic problem will still remain and a new solenoid might go the same way.
Someone with more experience of bike electrics must be out there?

Nick
 
Francesca is alive! Gently fiddled with the starter post and left the lead on without securing. Hooked the battery back up and vroom! Honestly, I was struggling with the new ground/ battery wires. Very stiff and setup for OEM lead acid. Had to really fight the memory of all the aux wires and my tiny Lithium. May have just been as simple as not a great connection for that circuit but, figured if the dash and electronics fired up, should be good. Just hope it's not a finicky starter post that I'll have to kick every time it won't start.
 
I would be interested how the bigger wires work out for you once you get everything back together.
 
Bones, almost forgot why I installed the new wires. My starter, which is a new Denso unit, was chugging. Especially when it was colder out. I know you have to warm Lithium batteries up in colder temps but mine was way out of spec. I would have to run the high beams for nearly 5 minutes, plus turn the starter multiple times before it would ignite. If I thumbed the starter too long, it would boot the ECU because the voltage dropped too low.

I was partially paying attention but, it turns over in 1 to 2 starter cycles now. I starter it about 5 times today and it was definitely crisp and quick. Could probably get marginal results from existing wires by cleaning the contact points and adding some di-electric grease. New ground, positive and starter wires were much heavier gauge.
 
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