1999 Fe600e electrical failure.

Wyatt · Sep 18, 2005

My 600 lost all power to the lighting system (i.e. head & tail light, turn signals, horn), whether the motor is running or not. Electric starter still works and the motor runs but everything else is dead. Any suggestions what the probelm may be?

Any help is appreciated.
Thanks, Daryn

berger · Sep 18, 2005

Fuse???

ned37 · Sep 19, 2005

ah no, mr berger, i'm guessing the worst case. bad stator like the one i had on my 400.
disconnect the leads and check resistance of the coils- bet they're zero.

nsman · Sep 19, 2005

Since the bike still starts and runs I think its a key switch problem ,bad connection or as Berger states possibly a fuse.

BundyBear · Sep 19, 2005

ned37 said:
.. guessing the worst case. bad stator like the one i had on my 400.

ned - Did you have a stator failure where the charging coils died but still had spark? If so your failure is a rarity. Stator failures normally affect magneto coils only.

Wyatt - What year model? You should be correct in thinking the fuse is OK if the starter works.

Most of them have a Bosch power relay (same as used for driving lights in cars) mounted under the seat to control power to much of the electrical system (not the start system though!) when the key is switched on. It should click on & off when you turn the key on & off. If it doesn't, check the wiring & connections to the relay coil terminals (no. 85 & 86 I think) and red & white wires on the ignition switch. Could be a crook ignition switch contact. Also likely a wire has either been pinched & cut between the steering travel stop or fractured internally where they flex around the steering head.

If it clicks, check the relay contact connetions (nos 30 & 87) & wires.

If it is any help you can find wiring diagrams in the downloads section or else here is a drawing of the wiring on my 600.

If you still can't find the problem, get your hands on a multimeter & post back.

Wyatt · Sep 19, 2005

I attempted to locate the power relay like the one shown in the 98 fe600e wiring diagram offered by Bundybear but my 99 doesn't seem to have one, one thats visible anyway. I never recall hearing a clicking noise in the past when turning on the ignition switch indicating the absents of a mechanical power relay.

When I check the wires from the stator to the rectifier with a multi-meter I get conductivity.

All the wires at the steering head area are okay.

The switch cluster on the handle bars is only a few months old.

I have had the fuse blow in the past and the entire system goes dead including the starter motor. The starter motor still works in this case and the fuse is fine.

There must be an "electronic" power relay somewhere thats gone bad.

BundyBear · Sep 19, 2005

Unless your bike has been changed from original there is no electronic relay. The wiring on these bikes is very basic. I have seen photos of the relay on models later than '98 so it is most likely your bike will have one. It should be mounted horizontally under the seat, just above the battery, on top of the top subframe rail on the LHS & under a bolt that is next to the bolt that the battery earth lead anchors onto . The relay is real hard to hear clicking - unlike the starter solenoid. You gotta have your ear next to it with the seat off.

It could be that a previous owner has removed it & rewired the power control through the keyswitch so that the battery doesn't get flatttened if you accidentally leave the key on. I modified mine that way but the drawing I posted was as it was prior to the change.

If your battery is charging OK (check for at least 13.5 to 14 Volts across it with the engine running) there is no point checking anything upstream of the battery eg stator, regulator, rectifier or associated wiring.

You mention it recently had a new switch cluster. Are you positive this is still connected up OK?

Wyatt · Sep 20, 2005

Problem solved.

Using a multi-meter I found a dead circuit in my new handlebar switch cluster, good call BundyBear you thought it might be the new switch. My next step will be to call Baja Designs and see if they'll exchange it for a new one.

Thanks everyone for taking the time to provide feedback.

Daryn

ned37 · Sep 23, 2005

glad i was wrong. lately, all the problems have been worst case type. and yes, i had this rare failure, 12v coils in the stator were open, lead wires were ok. new stator cured the problem.

BundyBear · Sep 25, 2005

Ned - Thanks for that. I think yours is the first that has a confirmed open circuit on the lighting coils. I guess it proves it can happen.

kneedown · Oct 7, 2005

I'm working through a similar situation on my FS. Weak light at idle, weaker light when revved. Fires fantastically on the button with a new battery, but a new stator will go in tonight.

Thanks to Motoxotica for keeping one in stock to get me going for the (wet) weekend ride! 8)

kneedown · Oct 10, 2005

Okay, new stator in on Friday PM and she popped right off without even a cough (had to double-check timing marks first, of course!). Charged nicely with bright lights and flashing signals, etc. Horn even worked!

I then rode off on Saturday morning to get her inspected (church was sponsoring a bike rally on Sunday). For those of you not in the East, it was raining. Hard. All worked well until the last water crossing before the bike shop. No charging, dim lights, etc. :x Luckily it dried out enough to pass state inspection, but no charging since then. Surely there must be a way to seal the system from rain/moisture!? Granted, these were severe conditions (I totalled over 12" of rain), but I really don't want to spend another $400 to pass inspection next year.

1999 Fe600e electrical failure.

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