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Old Aug 20, 2012 | 10:26 AM
  #1  
sean122774's Avatar
sean122774
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2nd Gear
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Default Starter Issues

My battery died on my 2009 XL1200N a couple months ago. It was an ongoing issue. So while I had some downtime I got some work done. Replaced the bars, doing a tank lift / coil relocation. Put the battery on a tender to juice her back up. But now I can't get 'er to start. Ignition switch primes the tank. But when I hit the starter button there is absolutely nothing. No click, zero. Here's what I've done:

1) Replaced battery
2) Checked all lines that I had disconnected after the wire tuck
3) Tested line continuity to and from the starter switch - OK
4) Tested line voltage to and from starter switch - OK
5) Tested starter relays - OK
6) Checked for blown fuses - OK
7) Did voltage drop test on starter per manual - OK

At this point I am at a loss. My next step will be having it picked up and looked at by a shop which I really don't have the $$$ for now after all the other work I've done.

Suggestions and possible fixes would be greatly appreciated!
 
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Old Aug 20, 2012 | 11:10 AM
  #2  
cHarley's Avatar
cHarley
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From: Boynton Beach, FloriDuh
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Does the starter solenoid control wire (usually a green wire) measure 12V at the starter solenoid post when you press the start button? If not, start tracing backwards from there. (solenoid > starter relay > start button)

The fact that you replaced the bars and did a tank lift makes for high odds there's a related wiring problem.
 
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Old Aug 23, 2012 | 08:22 AM
  #3  
sean122774's Avatar
sean122774
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2nd Gear
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Just following up with the solution for future readers. Guess I should have mentioned as well that I also replaced the clutch and brake levers.

Turns out the clutch lever was not making contact with a small safety switch / button on the inside of the housing. There should be a small nub on the inside of the lever that when the lever is fully depressed, triggers that button and allows the bike to start. My lever was missing that. Paid $110 just to find out this small issue...

Oh well, lesson learned. And at least it wasn't something major that would have cost more $$$.
 
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Old Aug 23, 2012 | 03:24 PM
  #4  
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cHarley
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From: Boynton Beach, FloriDuh
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If you had put the tranny in neutral, the bike should have started whether the clutch switch was working or not.
It's not a good idea to crank the bike while it's in gear with the clutch pulled in. Wet clutches don't fully disengage until the motor is running, which means when you crank in gear, your adding additional drag on the starter.

Glad you figured it out.
 
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