HOW TO: Test your starter circuit

Start with the bike on the center stand with side stand up and the transmission in neutral. You will also want the ignition switch turned to on and the kill switch turned to on. The numbers in the picture coincide with the steps listed below.

xj650 blog Wiring Diagram

1. Test the voltage at the battery. It should read at least 12.5 volts. Charge and retest as needed.

2. Using an old screwdriver, short across the two large terminals at the starter solenoid. This will bypass the solenoid and allow the starter to crank the engine. If the starter doesn't crank, perform a continuity test between the negative battery terminal and the engine case. If you read no resistance (or almost no resistance), repair or replace the starter. Otherwise, repair or replace the ground cables and retest.

xj650 blog Solenoid Shorting

3. Locate the pigtail from the starter solenoid and unplug it. Using a jumper lead, hook the Red/White wire from the solenoid to the battery's positive terminal. Using another jumper lead, hook one end to the solenoid's Blue/White wire. Momentarily touch the other end of this lead to the battery's negative terminal. If the solenoid is functioning properly, the solenoid should click and the starter should begin cranking the engine. Repeat this step several times to ensure the integrity of the solenoid. If nothing happens, repair or replace the starter solenoid.

xj650 blog Solenoid Pigtail

(h/t the bap3826)

4. If the solenoid checks out, hook your continuity tester between the battery's ground terminal and the Blue/White wire coming from the bike's wiring harness for the starter solenoid (solenoid pigtail unplugged). It should read an open state while the starter button is not pressed. When you push in the starter button, the tester should then read a closed state. If there's no change, inspect, clean, or replace the starter button switch and its ground and retest.

5. Using your voltmeter, hook its ground wire to the battery's negative terminal and its positive wire to the Red/White wire coming from the bike's wiring harness for the starter solenoid (solenoid pigtail unplugged). The meter should read 12 volts (approx.) if the bike is in neutral, and/or the clutch lever is squeezed and side stand is up with the key on and the kill switch on. If not, inspect the wire coming from the starter circuit cut-off relay for any breaks or chaffing. If the wire looks good, go to the next step.

6. Remove the left-hand side cover to gain access to the starter circuit cut-off relay. Using your voltmeter, hook its ground wire to the battery's negative terminal and its positive wire to the Red/White wire coming from the kill switch (starter circuit cut-off relay pigtail unplugged). The meter should read 12 volts (approx.) if the ignition switch is on and the kill switch is on. If not, you will need to inspect, clean or replace the 20A Main fuse, the ignition switch, the kill switch, or the wiring between them. If you measure 12 volts (approx.), go to the next step.

xj650 blog Starter Circuit Cut Off Relay
(h/t the bap3826)

7. Hook your continuity tester between the battery's ground terminal and the Sky Blue wire coming from the bike's wiring harness for the starter circuit cut-off relay (relay pigtail unplugged). It should read an open state while the transmission is in gear. When you shift into neutral, the tester should then read a closed state. If there's no change, inspect, clean, or replace the neutral switch and its ground and retest. If it checks out, proceed to the next step.

8. Hook your continuity tester between the battery's ground terminal and the Black/Yellow wire coming from the bike's wiring harness for the starter circuit cut-off relay (relay pigtail unplugged). It should read an open state while the clutch lever is released and/or the side stand is down. When you squeeze the clutch lever and the side stand is up, the tester should then read a closed state. If there's no change, inspect, clean, or replace the clutch and side stand switches and their grounds and retest. If they check out, proceed to the next step. (Note: some models may not have a side stand switch.)

9. If all previous tests have passed, replace the starter circuit cut-off relay and try to start the bike again. If it still doesn't start, have your bike exorcised of demons by a Catholic priest and retest as there's really nothing else that would keep your bike from cranking over.

(Written by Don Bangert Author of several How-To's and the blog, The Path Less Traveled.)

3 comments:

lanijo said...

Hello;
I just wanted to thank you for the excellent article you wrote on how to test your solenoid. I have looked all over the net, and nothing has been as descriptive and informative as your article. I just wanted to thank you. You should be sharing your expertise on a web it called ehow.com. They also pay a little too. Well Thank you again.

LJ Tuggle

lanijo said...

Hello;
I just wanted to thank you for the excellent article you wrote on how to test your solenoid. I have looked all over the net, and nothing has been as descriptive and informative as your article. I just wanted to thank you. You should be sharing your expertise on a web it called ehow.com. They also pay a little too. Well Thank you again.

LJ Tuggle

Silo Pup said...

Thank you for the article. It helps us out so much! Keep up the good work. I just bought an 1982 Maxim 650 and love it!