FE 550 starter circuit issue

tony951 · Mar 16, 2015

Hey guys - 2005 FE 550 runs great but starter just stopped working during a ride - also, headlight no longer turns on with bike off. With the bike running, the headlight pulsates. I just installed a new Shorai battery, which comes charged - no change in symptoms. Main fuse is ok. Seems like the charging system is faulty - where do I start looking?

Thanks in advance!

enginenumber · Mar 16, 2015

Hey there Tony,
had an 04 berg, had dramas for a long time with starter not working.

What I found was one of the cables on the battery, because it is riden offroad a lot must of flexed so much over the years, it started breaking the wires inside of the sheave , I could not see it from the outside.

How I picked it up was jumping straight from the battery to starter, when it started up , I then realised it was something to do with the cable. It was still 1/3 of it ok, but lost enough wires , it would not start the bike.

Maybe something easy to look at to start with.

OldMan · Mar 17, 2015

tony951 said:
...also, headlight no longer turns on with bike off.

Mine never did.

tony951 · Mar 18, 2015

Thanks you for the tip! I will try jumping directly from battery to starter and report back. May not have time till the weekend, however.

ned37 · Mar 20, 2015

check the fuse?

tony951 · Mar 20, 2015

Hi Ned - yeah I checked it and it looked fine. I'll report back after I investigate further this weekend.

tony951 · Apr 3, 2015

Well I finally got back to this. I tried a jumper btw the battery and starter - sure enough it turned over the starter. I also replaced the fuse w/new one just to be sure that wasn't it.

So, I'm going to investigate further and will report back with my findings. It must be a bad wire.

I guess one key is that my headlight and starter both stopped working (with engine off), and now headlight pulsates with engine running.

tony951 · Apr 6, 2015

Problem fixed! It turned out to be a loose wire in one of the connectors near the starter relay fuse. I just re-crimped it in place.

Now the starter works and headlight turns on with bike off, and no more pulsating headlight with bike running.

Thanks for the responses!

tourist · Apr 6, 2015

Great to hear! – and you can be sure that this thread will be useful for someone in the future. Thanks for posting up info.

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