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I recently acquired a low mileage (1,700miles) 2013 Forty Eight.
Bike wouldn’t start, strong clicking coming from the solenoid.
When activated manually, sparks fly from the solenoid (but engages and spins).
New battery checked all fuses and cables and ready to put everything back together.
However, I’m having some doubts on the grounds of the solenoid.
I read here its normal to measure no resistance between frame and starter cable due to low resistance of the windings & brushes. However, I doubt if it’s correct I don’t measure any resistance between 2/3/4/5 (see picture below) and frame.Anyone has a chance to check this? I’d be very grateful…
Measurements taken with all cables, connectors, battery, fuses… on bike disconnected
1) Battery positive connection = Not grounded
2) Start switch connection = Grounded (cable not grounded when disconnected)
3 / 4) Start switch cable = grounded
5) Solenoid to starter cable connection = Grounded (not grounded when 5 + 7 disconnected)
6) Solenoid housing = grounded
7) Starter cable = grounded
(Picture not taken from my bike)
Last edited by Wannes Smedts; Jun 25, 2018 at 07:02 AM.
Thanks for your insights. Will do and report back.
It just seems weird.. There's not much rebuilding / cleaning to be done (not my picture) on a new bike.
Correct, but there are no external connections left.
All has been disconnected, jump started the solenoid and starter.
Maybe the car jumper cables are too long or too thin.
Will put everything back together first.
The solenoid sounds bad. Check continuity on the switch wire for the soleniod so you know the starter button is working or at least the wiring is all good. Sounds like the part in the solenoid that tells it to send power to the starter is bad.
Solenoids are simply heavy duty relays, however the solenoid gets it's power for the windings from the start relay, the spark show sounds like the power wire from the battery or the power wire to the starter. If you are jumping across the terminals to start the starter it would also cause a spark show as well. If the solenoid is not getting power from the start relay it will not function. Check the relay, will the bike actually start if it was jumped across the solenoid terminals? If it doesn't look at the security system.
* Jumper cables hooked up to starter (solenoid disconnected): starter spins
* Jumper cables hooked up to solenoid + post and starter - post (ground), manually activated solenoid (pushed): starter engages and spins (but slower)
* Start button and cables: good, no short
* Start button connection (small bottom wire) on solenoid: cable not grounded when disconnected, terminal is grounded
* Start relay replaced before, no difference
Solenoid should never be hooked to bat negative, it only supplies the positive connection to the starter, the test for the solenoid is to jump with a metal object (screwdriver) across the terminals. Follow the FSM for testing and quit trying to invent your own test. All you are doing is smoking your solenoid contacts as you are shorting them out. You also didn't answer about the engine running not starter spinning.
No the engine wasn't running since I unhooked all cables, (spark) plugs,... to eliminate interferience on testing.
Engine did turn though (but not running)
Didn't short the contacts out:
Negative cable was hooked up to ground post on starter (as intented)
Positive cable hooked up to positive terminal (as intended)
Used the 'screwdriver' trick, not by shorting the terminals with a screwdriver but by pusing the solenoid plunger inwards (which yields to the exact same results)
Copper contacts and washer were cleaned and in very good shape.
My original question was if all internal contacts of the solenoid (secondary terminal, start connection) are supposed to show being grounded when NOT connected to the starter by the cable (secondary solenoid terminal -> starter) and only by it's case. If not, I guess that means something is shorted inside.
If I'm missing the point, your clarification is much appreciated.
Last edited by Wannes Smedts; Jun 26, 2018 at 08:04 AM.
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Checking solenoid grounds
