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?

Fuse turned out to be blown. The headlight switch is the cause... will have to pull it off and inspect

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

Rainerio said:

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

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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

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?

Taffy said:

if true it would be a first time ever.

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

Taffy

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You were right haha, have bought a starter repair kit for the bike. Anything else worth replacing when I pull the left side cover off to install it? Bike has 210 hours and 9000kms