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Post by dick on Apr 20, 2022 12:42:56 GMT
not sure whats going on with the starter solonoid/s... came out to the bike a few times in winter, and on pressing the starter button...nothing,..oh well maybe flat battery....then charged the battery, but same thing, nothing, just a click from the solonoid... replaced the solonoid in febuary with a new aftermarket item, hit the button, bingo ! starts straight away until today...hit the button, same thing, just a click..so connected my fully charged jump pack, still the same result, just a clicking solonoid.. bridging the solonoid starts the bike straight away, so i am thinking maybe the postive lead is at fault ? all connections are nice and clean and firmly connected not being very well versed on leccy things, i had already ruled out the clutch switch and the starter button, checked all the fuses then moved backwards to the solonoid... anything i should check next ? thankfully i have a kickstart, so its not a big deal  |
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Post by duffer on Apr 20, 2022 14:38:50 GMT
Check your earth lead. Take it off the frame,clean it all for a good connection. Bolt it back tight,then repaint any bare metal.
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Post by buster on Apr 20, 2022 15:54:15 GMT
if the earth lead is ok you could try tapping the starter motor with a lump of wood. if it jogs over and starts using the thugs technique then I'd have a look at the brushes
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Post by dick on Apr 20, 2022 18:10:23 GMT
if the earth lead is ok you could try tapping the starter motor with a lump of wood. if it jogs over and starts using the thugs technique then I'd have a look at the brushes when i bridge the solonoid it starts straight away, so would assume said brushes are fine, but its something else to fanny about with on a sunny day...or just use the kick start !  |
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Post by dick on May 30, 2022 17:33:54 GMT
being lazy i have been using the kickstart to start the bike...but was a nice day outside so thought i would have another go...no joy  replaced the lead from the starter to the solonoid fitted new starter motor bushes replaced the battery to solonoid cable fitted new 12v gel battery none of the above made any differance, i replaced each part one at a time, checking as i went along when pressing the starter button on the handlebar, the relay is clicking, and as previously mentioned if i bridge the solonoid, then the bike spins over, which suggests the wiring is fine... am i right in thinking that the solonoid will only switch providing a good 12volts is available..i.e if the voltage was only say 9 volts, it wouldnt work..or maybe just click like its doing ? so.....the solonoid is just a heavy duty switch, how does the voltage from the starter button trip the solonoid into making the contact to spin the starter over ? [ i have never seen inside a solonoid ] but i think the old one will be attacked very shortly to find out i have temp joined the clutch switch wires together to eliminate the clutch switch from the equation any futher thoughts ? |
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Post by johnjones on May 30, 2022 17:54:55 GMT
First get a wiring diagram and study.
Check how clutch switch works, switch contacts touching IE continuity, to allow solenoid to be energised, but you do say the solenoid clicks when engine in neutral and button pressed.
Solenoid should also click when engine in gear and clutch pulled into handle bar.
A safety function brought about by the switches and diode by fuses.this is the solenoid energiser circuit only.
The solenoid is a heavy duty relay allowing a small current via start button to energise an electromagnet to switch a heavy duty switch for the starter motor. The solenoid is possible to take apart, inspect, clean and reassemble.
Disconnect starter main wire from solenoid and make contact with the main battery positive lead on the solenoid, engine in neutral...does the starter motor now work ?
This test tests the earth, starter motor, motor lead and main battery positive lead from battery.
Feedback so far, over....
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Post by dick on May 30, 2022 18:43:50 GMT
First get a wiring diagram and study. Check how clutch switch works, switch contacts touching IE continuity, to allow solenoid to be energised, but you do say the solenoid clicks when engine in neutral and button pressed. Solenoid should also click when engine in gear and clutch pulled into handle bar. A safety function brought about by the switches and diode by fuses.this is the solenoid energiser circuit only. The solenoid is a heavy duty relay allowing a small current via start button to energise an electromagnet to switch a heavy duty switch for the starter motor. The solenoid is possible to take apart, inspect, clean and reassemble. Disconnect starter main wire from solenoid and make contact with the main battery positive lead on the solenoid, engine in neutral...does the starter motor now work ? This test tests the earth, starter motor, motor lead and main battery positive lead from battery. Feedback so far, over.... yep, poured over the wiring diagrams/workshop manuals etc elimated the clutch switch from the circuit by joining the two switch wires together, effectively removes the switch for testing puposes if its dry tomorrow, will have another look thanks |
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Post by dick on May 31, 2022 10:46:58 GMT
ok, hopefully problem solved..turns out [ thus far ] to have been the solenoid, the original wiring was fine [ allthough i have replaced some of the old leads with new ones ] after watching a couple of you tube clips, i now understood more of how these solenoids work internally  as johnjones suggested, the original solenoid is serviceable to an extent, but in the last 44 years somebody had already been inside it, i assume to repair it once before, so i couldnt, without damaging the case, get to the coil winding and the plunger in the lower half of the solenoid, but i cleaned all the brass contacts, replaced one of the leads [ yellow /red ] put it all back together, stuck 12volts to it, and now it has a strong click, instead of nothing when i first tested it as the original solenoid is no longer readily available, i purchased an aftermarket one, which worked out of the box for about 6 weeks and then it gave up the ghost, but after watching the aforementioned you tube clips, its hardly suprising they only cost a tenner or so...weight wise, the original one is quite heavy and built strongly, the aftermarket ones are very lightweight and made of monkey metal so, as a backup i found an original solenoid that hasnt been apart, and is has been tested for £8 [ inc p+p ] it would appear that the exact same solenoid was used over a wide range of bikes, kwaks, suzukis, hondas etc, and aside from the exciter wire colors, any of these solenoids would do the job just fine so, thanks to all that offered help and advice  |
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