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Absolutely DEAD? No electrics at all?

Joined Sep 2011
282 Posts | 1+
I rode across town and left the bike idling while I fed the horses. I exited the barn put the bike in gear, and started to let the clutch out. I moved about five feet and everything went dead. Not a flicker from anything. The lights are all dead, the ignition switch activates nothing and there is no flicker of electrical life period. I pulled the seat, checked all of the fuses, and found not a single fuse blown? The bike is about four months old, and is a 2011 FE570S US model.

I've looked at the diagrams and the only thing that I see from the battery that all of the power runs through is the starter relay. I see there is a way to jumper around that relay for the purpose of testing the lights. Other than the starter relay, can anyone think of what I should be looking at? Has anyone else had this problem?

I'll be going to pick the bike up in the morning and working on it tomorrow. Any ideas would be appreciated. I know the bike is under warranty, but my dealer is over 6 hours away, so I will try to diagnose the issue myself and then contact the dealer to see if he will send me the part.
 
There has been a few posts on UHE where the battery terminals are loose.
The Voltage Regulator turns the Power Relay on that feeds power to most of the eletrics. You can short out pin 5 and 6 in the XC1 connector to get the Power Relay activated. Bit of info in this post on how to do that:
Bypass power relay for testing electrical on fe 570 -09

Using 1 Jumper Lead (The things you use to start a car with a flat battery) you can short out the 2 big posts on the Starter Relay and the Starter Motor should spin. The Posts are marked "B" and "M"
Using a Volt Meter you can Check the Battery voltage. Try checking it at the "B" Post on the Starter Relay (That is the +12V from Battery) and a bolt on the Frame (Earth).
Double check that 20Amp Fuse in the Starter Relay.

Let us know how you go.
 
Davo said:
There has been a few posts on UHE where the battery terminals are loose.


I would start here. Mine did this in the middle of the scrub one day and the day turned into a nightmare. All for a loose terminal.
 
The mystery is solved, sort of? First, I checked the reistance at the starter selenoid, and everything was in order. I manually engaged the starter. The battery was delivering 12.4 volts to the selenoid, but there was no other voltage anywhere else on the bike.

Using the voltmeter, I decided to begin checking fuses. I had visually inspected the fuses last night and found no obviously blown fuses. So using the voltmeter, I found fuse number five, which according to the manual is not used for anything, was not delivering voltage across the fuse. I pulled the fuse and inspected it. Visually, it looked fine. I pulled out my magnifying glass and a bright light and reinspected it. Viola, there was a crack in the fuseable link. If I wiggled the fuse blade, I could see the crack. There is no visible evidence of heat on this fuse, there is no carbon anywhere along the fuseable link. I suspect the fuse failed from vibration and having a blade that was slightly loose in the plastic?

Now the sort of part. After replacing fuse #5, everything came back on and the bike is good to go. According to my manual, this fuse is not used? I suspect that somehow, my fuse block got wired wrong at the factory because fuse #5 seems to control all of the items the manual claims fuse #4 controls. I will probably pull fuse #4 to see if it disables the items it is suppose to or if it does nothing.

Anyway, replacing the broken fuse which controls nothing fixed the problem. Thanks for the great responses.
 
I did a voltage check on my bike and all five of the fuses are hot? So much for the manual being correct.
 

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