Bike quit...in midst of troubleshooting
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Thread: Bike quit...in midst of troubleshooting

  1. #1
    Senior Member blivy's Avatar
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    Bike quit...in midst of troubleshooting

    Bike just quit on me. Ran it earlier, and when I went to start it on way home I THINK the head light came on for a sec when I turned the key and then nothing.
    No sound, didn't even hear a pop (I assumed fuses).

    Checked main 20 amp fuse and it was fine. Checked fuse under the plate by the key where the 10 amp fuses are.

    Brother came by and brought some glass tube replacement fuses (he had only 30 amp, but I figured they were fine for diagnostics). Replaced and still nothing.

    Checked battery. Reading 14.6 which I think is right for my ballistic.

    Brother had truck nearby so I loaded bike up and took it home for further troubleshooting.
    Had brand new starter solenoid and ignition (for brothers bike) put both on and checked after each.
    Nothing.

    Looked for loose wires on harness.
    Didn't see any besides my black and white kill switch wire which I had disconnnected a while ago when my kill switch got faulty.

    Got into headlight bucket and found these 2 brown wires that are coming from the main harness. See attached pic (they are the two brown ones that share one female connector)...From my wiring diagram I see that these are tied to the ignition but can't tell from the diagram what they are supposed to connect to. Strangely, I don't see any obvious wires that should mate into them.

    Any ideas? Really hoped to take my wife on an Easter ride today.
    Thanks,
    Blivy
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    Last edited by blivy; 04-16-2017 at 10:23 AM.

  2. #2
    Senior Member rscottp's Avatar
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    Did you check the actual ignition switch? That connection can corrode and cause problems. Also did you upgrade the 20A fuse to the blade type? Others have said that the old main fuse can look ok and not be.
    1981 CX 500 Deluxe
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  3. #3
    Senior Member blivy's Avatar
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    When you say the "actual ignition switch" are you meaning where you put the key in and turn?
    as to your second question--I've got the blad type in there.
    Thanks,
    Blivy
    1979 CX500 Custom, Athens, Georgia
    Rebuilt Left Cylinder Head (2011)
    Rebuilt Starter (2011); Re-enameled tank (2011); Rebuilt Carbs (Larry method) (2012);
    Triple by-pass performed (2012);
    Upgrade to G8 stator and Ignitech (2012);
    Rebuilt oil pump and new oil chain (2012);
    Stripped and painted frame and wheels(can job) (2012);
    Re-greased/lubed rear drive and rear drive splines (2012);
    8 cell lithium Ballistic battery (2014); Upgrade to dual pot brakes with SS line (2014);
    New Shinko 230 tires (2014)
    New EBC clutch springs (2015); Rebuilt clutch cable assembly on clutch cover case (2015);
    New throttle, clutch, and choke cables (2015)

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  5. #4
    Senior Member rscottp's Avatar
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    Yes, the keyed ignition.
    Last edited by rscottp; 04-16-2017 at 12:55 PM.
    1981 CX 500 Deluxe
    1986 Yamaha Radian YX600
    Martha'a Vineyard, Ma

  6. #5
    Super Moderator Sidecar Bob's Avatar
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    That brown wire connects to the tail light. It is for a small bulb in the headlight in parts of the world where parking lights are required. In North America it isn't supposed to be connected to anything.

    Along the lines that rscottp is thinking, look at the headlight (or the instrument lights if it is dark enough to tell) while turning the key on & off and working it back & forth and jiggling it to see if the light comes on or flickers. If it does you need to either clean or replace the keyswitch.

    Other possibilities include a loose battery cable (check both ends of both cables) or a bad wiring harness ground connection.
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  7. #6
    Senior Member blivy's Avatar
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    Thanks y'all.
    Ignigition switch/key switch (where you put the key in and turn) is brand new. Just installed.
    checked both battery cables and made sure they were tight and that the terminals and connections were clean.
    took a wire drill brush and cleaned off my ground connection and reattached firmly.
    just for shits and giggles I replaced the main fuse with another spare. Still nothing.
    Still Showing 14.65 volts on the battery but can't get anything as much as a light to come on when I turn the key to the on position. (This was also the case before I replaced the ignition with the new one).

    Any other ideas?
    Thank's y'all.
    blivy
    1979 CX500 Custom, Athens, Georgia
    Rebuilt Left Cylinder Head (2011)
    Rebuilt Starter (2011); Re-enameled tank (2011); Rebuilt Carbs (Larry method) (2012);
    Triple by-pass performed (2012);
    Upgrade to G8 stator and Ignitech (2012);
    Rebuilt oil pump and new oil chain (2012);
    Stripped and painted frame and wheels(can job) (2012);
    Re-greased/lubed rear drive and rear drive splines (2012);
    8 cell lithium Ballistic battery (2014); Upgrade to dual pot brakes with SS line (2014);
    New Shinko 230 tires (2014)
    New EBC clutch springs (2015); Rebuilt clutch cable assembly on clutch cover case (2015);
    New throttle, clutch, and choke cables (2015)

  8. #7
    Senior Member MCReviver's Avatar
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    Try turning the handlebars full left and right while trying the key.
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  9. #8
    Senior Member blivy's Avatar
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    Curious...about to run out and try that, but would that just be checking for a loose connection?
    1979 CX500 Custom, Athens, Georgia
    Rebuilt Left Cylinder Head (2011)
    Rebuilt Starter (2011); Re-enameled tank (2011); Rebuilt Carbs (Larry method) (2012);
    Triple by-pass performed (2012);
    Upgrade to G8 stator and Ignitech (2012);
    Rebuilt oil pump and new oil chain (2012);
    Stripped and painted frame and wheels(can job) (2012);
    Re-greased/lubed rear drive and rear drive splines (2012);
    8 cell lithium Ballistic battery (2014); Upgrade to dual pot brakes with SS line (2014);
    New Shinko 230 tires (2014)
    New EBC clutch springs (2015); Rebuilt clutch cable assembly on clutch cover case (2015);
    New throttle, clutch, and choke cables (2015)

  10. #9
    Senior Member nolimitz's Avatar
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    or a broken wire in the loom
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  11. #10
    OCR
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    Senior Member OCR's Avatar
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    Possible that the starter switch button is the issue.
    Try cleaning it.
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