Boxerworks.com

Gidday Steve,

Reading and watching with interest here on this one mate, I wish I could offer a little help but electrics twist my mind to much, am finding the problem solving intersting to follow with the posts......

Yep, we're all rootin' for yer, Steve.

Tim's right. You need some more volts. I'd attach some if I could. Hopefully the battery will be better charged this morning, otherwise you'll be up for a new one I fear.

Yes, the 12.48v although indicated as full on the charger, wasn't enough. An overnight charge brought that up to 13.05v, and unfortunately I'm still getting the clacking.

Jumped from the car, it was still clacking.

So, I'm guessing the battery and maybe something electronic is fried from the voltage spike with the loose -ve? The ICU?

The battery should be ok. Just checked Brunhilde - 12.7V and no problems starting.
Starter solenoid would be my guess. Do you have a spare starter you can throw in?

Airbear wrote:The battery should be ok. Just checked Brunhilde - 12.7V and no problems starting.
Starter solenoid would be my guess. Do you have a spare starter you can throw in?

No unfortunately. Just spoke to BM Motorcycles, and he headed to that conclusion also. He didn't think there'd be a problem with the icu either.

Ross Gregory might have a starter. (0421 057 488)
Hans might be worth a try if you want to borrow one while you fix yours. (0415 717 192)

Thanks Charlie. I'd already emailed Ross.
I'm off to work this arvo, so no chance to follow up 'til late tomorrow night. I doubt I'll get this sorted before Friday, as mostly working . I hope I'm wrong.

I've been off getting stuff to securely tape up the loom that I've opened, and removed the starter cover. i cleaned the solenoid contacts, but that's all really.

Is there a way to remove the solenoid without removing the starter? In all my years riding these bikes, it's never been something I've had to do.

SteveD wrote:Thanks Charlie. I'd already emailed Ross.
I'm off to work this arvo, so no chance to follow up 'til late tomorrow night. I doubt I'll get this sorted before Friday, as mostly working . I hope I'm wrong.

I've been off getting stuff to securely tape up the loom that I've opened, and removed the starter cover. i cleaned the solenoid contacts, but that's all really.

Is there a way to remove the solenoid without removing the starter? In all my years riding these bikes, it's never been something I've had to do.

Since you have the starter cover off, try testing the starter by using a screwdriver to short across the positive terminal (big wire from battery) to the other connector with a black wire on the solenoid. This bypasses the relay, switch, wonky wiring, etc.

"Since you have the starter cover off, try testing the starter by using a screwdriver to short across the positive terminal (big wire from battery) to the other connector with a black wire on the solenoid. This bypasses the relay, switch, wonky
wiring, etc." As Tim said,
This would be a good fault locating procedure.

On an off chance, and unless you're absolutely sure of the condition inside the housing...

Before you start tearing the loom apart. its well worth dismantling the housing and checking the contact pins that mate with the offending multiplug to ensure that they are firmly attached to the board and electrically solidly connected. The multiplug is quite hard to insert and its quite possible for one or more of the pins to work loose.

Rob