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May 30th, 2016, 11:50 PM   #1
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FE550 Starter won't work, battery charged and fuse good

Hey

I have an FE550 and the starter was working fine, albeit the sprague clutch was well worn out...

I cranked it a heap in the shed the other night and the battery ran down a fair bit but it eventually started

Now it's fully dead, the starter will not click or turn over at all. I have charged the battery up, pulled and reset the fuse (wasn't blown) and the speedo and everything else were working anyway.

Multimeter on the starter shows no voltage whilst holding down the button.
Is the next step to connect the starter directly to a 12V power supply I have?
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May 31st, 2016, 12:48 AM   #2
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Just poor HT leads methinks. clean all the HT leads up.

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May 31st, 2016, 01:30 AM   #3
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Fuse turned out to be blown. The headlight switch is the cause... will have to pull it off and inspect

Last edited by mattwilkinson; May 31st, 2016 at 03:04 AM.
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June 3rd, 2016, 03:15 AM   #4
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Issue has returned, so what happened is my friends headlight would not work. He installed his switch on my bike and my headlight did not work, which located his issue.

We reinstalled my headlight switch and all was good, the next time I went to start my bike it blew the 10A fuse. and again and again, It is intermittent in that I can plug my switch back in and it will start fine numerous times and then randomly blow it, I have not ridden the bike in the last 9 months.

Is this just a major coincidence or has his switch either damaged some other part of my bike or damaged my headlight switch?

Thanks

I need to go buy more fuses and test to see if it still blows with the turn/light switch not installed. The problem is that it is an intermittent issue and is difficult to recreate, The bike hasn't been ridden for nearly a year now
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June 3rd, 2016, 04:13 AM   #5
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Check all grounds/earth clean then up , retighten them , the reason the fuse blows is because that part of circuit is drawing more amps then the fuse can handle. Still could be a switch or the starter check clean or replace. Only thing left I can think of would be a bear wire grounding somewhere. Hope this helps

Last edited by Rainerio; June 3rd, 2016 at 04:54 AM.
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June 3rd, 2016, 04:55 AM   #6
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Originally Posted by Rainerio View Post
Check all grounds/earth clean then up , retighten them , the reason the fuse blows is because that part of circuit is drawing more amps then the fuse can handle. Still could a switch or the starter check clean or replace. Only thing left I can think of would be a bear wire grounding somewhere. Hope this helps
Replaced my battery today with another Yuasa which didn't fix the issue.. I cleaned up the wires so they are making good connection.

I guess I will just have to do some trial and error, in my head it seems very strange a faulty switch could cause a malfunction elsewhere on my bike..

If it changes anything, when the bike is running the brake light is on the entire time.
I have tried unplugging the front and rear brake switches seperately which did not solve the issue


The fuse blows when the bike is not running, I don't think it has blown whilst starting before

Last edited by mattwilkinson; June 3rd, 2016 at 05:16 AM.
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June 3rd, 2016, 07:49 AM   #7
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With the brake light being on all the time, I think Rainerio is on the money. You have wires shorting somewhere in the harness. Look for damaged harness somewhere.
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June 4th, 2016, 12:30 AM   #8
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Thanks all, turns out it was the 3 pin connector into the starter relay, the wires had rubbed through there and were touching.

As for the rear brake light, I am not sure why it would not be working. Would it be another short in the system somewhere? If I unplug both the brake switches does the system automatically light up the brake light the whole time or should it just be on running tail light the whole time?
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June 4th, 2016, 03:15 AM   #9
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Not clear on that rear light problem? But it's a process of elimination I start with the tail light is it the right one? Check all connectors for earth might find that shouldn't be. If bike is stock get a wiring diagram it's the fastest way. Most problems are bad connections lose,rusty or chafing wires
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June 5th, 2016, 02:53 PM   #10
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Originally Posted by mattwilkinson View Post
Fuse turned out to be blown. The headlight switch is the cause... will have to pull it off and inspect
if true it would be a first time ever.

so: 'no, I don't think so'.

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