2014 TE300 Starter Issues

Good Day all,
So over christmas i installed a new starter Motor, Bendix, transfer gear, starter relay and battery.
Tried starting it cold engine turned over slowly but would not fire. Tried it when warm and the starter relay went and its never even started the bike!
I have noticed 1 of the wires going the the relay plug (white/Red) has a slight bit of copper showing but cable is still in tact could this be causing a issue or are there any more parts that need changing ie flywheel or clutch bearings?
Really had enough now, there no wiring diagrams anywhere just want my e start to work :cry:
Any help is appreciated!
Alex

ede said:

• The cables in your circuit aren't damaged (short circuit via frame)?
• Your battery has enough cold cranking amps (CCA)? You can test it when you connect a car battery to your relay. It should have enough cranking amps to start the engine.
• Check if all ground wires are connected properly! Often ground is not good enough due to broken cables or dirty contact plugs/pins.
• How is the circuit between starter motor an battery closed? Electrically via engine and frame? You can bypass the frame with an additional cable between engine and battery to improve ground contact.

Click to expand...

Hello,
I'll Have a look tonight, take tank off and trace wires and do a continuity check see if there all ok they are double wrapped so should be ok.
The plug doesn't look in the best condition bit green - new loom another £40 +vat and p+p :banghead:
The Battery is brand new 12v 80cc currently holding 13V
Might try adding another ground too see if that helps the issue.

Thanks for your help will keep you updated

ede said:

• The cables in your circuit aren't damaged (short circuit via frame)?
• Your battery has enough cold cranking amps (CCA)? You can test it when you connect a car battery to your relay. It should have enough cranking amps to start the engine.
• Check if all ground wires are connected properly! Often ground is not good enough due to broken cables or dirty contact plugs/pins.
• How is the circuit between starter motor an battery closed? Electrically via engine and frame? You can bypass the frame with an additional cable between engine and battery to improve ground contact.

Click to expand...

On the relay plug does anyone know which one is the earth one? i have red/blue, red/yellow, and a slightly larger red/white.
Again having no drawings doesnt help.

ede said:

Hi Briceyberg,
the 2014 Husabergs should be pretty much the same as 2014 KTMs. I found the repair manual with wiring diagram (attached). Wiring color is not the same - but you can trace the cables.

I didn't attach the full manual since its 72MB, but you can find them here: https://kristofsx.com/

Click to expand...

Thanks my mates got a ktm so i can print it off and edit wire colours to suit my bike if i need to lol top man!

Hello little update,
So I have checked the wires and voltage going to and from the starter switch both reading 2.5v with no shorts, I've also tested the starter switch too which is fine.
I checked the voltage regulator to see if it was faulty but it stops the voltage at 14.5v so that seems to be working. I have ran a separate earth and still no voltage from the starter side of the relay so I have spoken to the company whom I purchased the starter relay from asking them to refund me and will purchase a decent oem instead.
Will keep you all updated with the results.
Just as a thought is there anywhere you can buy new connector for the starter relay rather than buy a new loom?

Success!!

So it did turn out to be a dodgy relay, but not the relay itself... it was the bit which connects onto the relay taking the fuse. The spade connections weren't aligning up and the fuse wasn't actually seating correctly. After a few minutes of fiddling fuse was in and starts lovely!