STILL having start problems. Electrical?

[Milo_357]

I'm having some kind of electrical issue, and hoping someone might recognize the problem.

My bike is a 1982 R65.  This happens when the bike is cold.  Turn on the fuel, set the choke,  it is in neutral..  All of my engine lights are on and bright on the tachometer.  Then I hit the starter button, and the motor turns over a couple times.  I let up, and hit the starter again (this is how I have always started the bike), but now EVERYTHING DIES on the bike. Instrument lights go out, and it won't turn over at all.

The battery shows 12.2 or so volts.

This does not happen when the bike is warm and has been running.

Today, I put a charger on the motor and started charging.   Suddenly the  tach lights lit back up, very brightly.  The bike started right up.

I DID replace the ignition switch.  I mechanic friend suggested this,
though he does not have a lot of airhead experience.  Also, there was
one wire that was not plugged in to the back, a green wire with a
black line.  I was told this was not necessarily required to be
plugged in.  I need to look at my wiring diagrams.

As you can imagine, I don't want to ride to work and have this happen, I won't have access to a charger.

Anyone have any idea what is going on??  I didn't have this problem last fall.

Thanks,

Dell

[Bob_Roller]

What is the battery voltage when you are using the starter ?

With a healthy battery, it shouldn't drop below 10.5 volts during starter operation, on a normal start .

When you get the total failure, does the tail light still operate ?

This light comes directly from the fuse, doesn't shut off when the stater is used .

The green wire with black spiral band, is for internal lighting for accessory instruments, clock and voltmeter and shouldn't be connected to the ignition switch .

[montmil]

Dell, it's a mystery.

Next time you're having the "lights out" issue, open the seat and put a fingertip on the starter relay. Try the start button. Do you feel the relay "clicking"? Most or all of the power in the electrical system passes through the starter relay at one time or another.

The lights are supposed to turn off while the starter is cranking the engine but they return when the engine fires. It's part of the electrical system design.

I'm wondering if the starter relay is experiencing sporadic failure; sticking in position.

Try removing the starter relay and cleaning the spades and the attach block contacts. It's a PITA to get into the tiny spade slots but your problem could be corrosion on the relay connections. This is a freebie test and check. I would hold off throwing new and expensive parts at the scooter until some further investigation is done.

Also, do not be tempted to try a "fits all-does all" relay from your FLAPS. The BMW relay has that lights cut-out circuit mentioned earlier.

Continue checking continuity of all switches n' buttons in the starter circuitry. You may wish to disconnect the battery while cleaning up connections.

[smiley=2cents.gif]

[Milo_357]

Bob & Monte,

I'll try all of this when I get home this evening.  I'm also going to try to get the battery loaded tested, clean all the leads, and doublecheck the ground wire.

I'll let you know, and THANKS!

Dell

[Milo_357]

Hey guys.  Looks like the problem with my bike may have been the ground wire.  Seems the PO at some point to the washers off and forgot to put them on.

Anyway, I didn't have the lock washer (forget what they are called), but a second thicker washer worked just fine, and the bike started yesterday and today with no hick-ups at all.

Thanks for the help! Yes, I feel stoopid.

No if I can just get my carbs synched...

[tvrla]

Hey, there's an excellent tech in Gatlinburg - his name's Anton. Know him? It might be worth visiting to pick his brain a little. Maybe you could clean some parts or help in some way in exchange for his advice.