Hello all,
I was preparing to ride (1994 900ss) this afternoon but have unfortunately run into an electrical issue. As I turned the key from "off" to "on" all lights came on and the fuel pump started running as normal. As soon as I tapped the starter, I heard a pop and all electrical items shut down. No power.
I figured that I simply blew a fuse but was surprised to see that all were fine including the charging fuse. Following troubleshooting instructions in my Haynes manual, I next checked the ignition switch by following its wires to the general relay. With the ignition on, all of the sockets were powered, so I figured that I had a bad relay. I installed a new relay, but there is still no power. Now I've hit a wall. Any ideas on what to check next? Thanks.
Something similar happened to me. After doing what you did, I decided to pull the starter and after popping the alternator cover, discovered that my flywheel had sheared off. It was a Ferracci lightened flywheel installed by the previous owner. I happened to have a spare, stock unit that I installed and everything has been fine since.
I don't know much about this stuff but I think yours sounds like its probably the round relay unit located under the airbox. All connections tight? You checked the relay up front too?
Is there no power to the starter or no power anywhere? You indicate that there was power at the ignition switch.
The starter solenoid white connector falls off easily, also moisture gets under the rubber covers of the starter motor and corrodes the terminals. I have seen the terminals eaten completely off the stud on the starter motor.
If you have no power anywhere after the ignition switch, try borrowing an ignition switch from any one else. Try taking the switch gear on the handlebar apart and check the kill switch. The switchgear comes apart easily and you can check if something shorted out the kill switch.
That is all the suggestions I can think of.
Good luck, Dan
First, I'd like to say thanks to you guys for helping me with this. I printed out your suggestions and took them to the garage to further narrow down the problem.
Since the electric failed when I hit the starter button, I figured that I would check the starter, starter relay, and fuel pump. I unplugged the fuel pump connector underneath the tank and the positive lead from the starter relay to the battery. When I turned the key from off to on, all of the annunciator lights, headlight, and taillight came on. Good. Next, I plugged in the fuel pump (after cleaning the connectors). I again turned the key from off to on and all of the lights came on and I heard the fuel pump running. Progress. Finally, I unhooked the starter electric connection (cleaned it this winter - good shape) and reconnected the lead from the battery to the relay. When I pressed the starter button, a normal sounding click was heard.
So, I thought "Great, my starter took a crap." Just for the heck of it, I reconnected the starter and to my surprise she fired up normally! Ok, so I tried it again. To make a long story short, its working normally now.
Here's my guess: I cleaned every ground and connector I came across, however, none looked very bad (she's never slept outside). Could the sum of all of the mediocre 13yo connections be enough to shut the system down? Or could the starter or starter relay have been stuck in a state that could drain the battery below the voltage necessary to run anything?
In my more than 34 yrs of mechanical experience...MOST..electrical problems are bad grounds!!!! But, that still doesn't stop me from going crazy by looking for other problems!!
almost the same thing happened to me yesterday..... almost home,,, rolled on the throttle, and then she just died on me... was just like running out of gas.... pulled over. Blew the 15 fuel pump fuse,,, put in a spare, turned the key and the pump ran, then tapped the starter and half a crank later a little pop..... one more fuse gone..... was lucky to be really close to home.... heading out to the garage in a bit to start checking it out..... anyone with similar problems/solutions welcome to jump in..... thanks....................
[quote=lilredducati;382910]almost the same thing happened to me yesterday..... almost home,,, rolled on the throttle, and then she just died on me... was just like running out of gas....quote]
Hmmm, after reading your post I'm going to start looking at all of my wiring a lot more closely.
No electric after tapping starter
It was a Ferracci lightened flywheel installed by the previous owner. I happened to have a spare, stock unit that I installed and everything has been fine since.
But, that still doesn't stop me from going crazy by looking for other problems!!
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