XR650L Not starting, no cranking

jrsride2002 · 10-04-2012, 03:28 PM

OK, so I took a trail ride up in Yosemite. Woke up, rode for about 45 mins, I crashed. Brushed myself off, picked up the bike, fired up and continued on. I rode for about another 10 minutes when I stopped to verify if I was on the correct trail, via a map. I was, I hop on the bike, nothing. No cranking, no clicking from the relay(which I never heard before, but read about it). Bump started the bike, and everything was back to normal.

I stop again for lunch. Eat, finish, jump on the bike, NOTHING

Bumb started again, bailed out to camp, no stops, just made it to camp.

Now im home, working on it....... Working on it.......................Working on it........
I pulled the seat, checked to wire to the start for breaks/cuts. Its good, a little wornout but shouldn't effect it yet. All the fuses are in good shape. Took a hammer and tapped the starter. The turn sigs work just fine in the garage. Headlights(aftermarket) no issues. My grounds look good. Bypassed safeties years ago.

WHAT COULD IT BE?!?!?!

Im at a total loss, please help, thanks,

~Junior

mcma111 · 10-04-2012, 03:41 PM

Sounds like the right handle bar switch assembly.

jrsride2002 · 10-04-2012, 04:18 PM

I tested with a completely new/separate starter switch setup(I have a spare)

~Junior

smokeeater495 · 10-04-2012, 04:21 PM

Kick stand switch?

Ben99r1 · 10-04-2012, 04:24 PM

I had this happen to me. For me it was a relay located in the head light fairing/ shroud. I don't know what its called but take off the shroud and fallow the wires from starter switch down to where it meets the harness. It will be sitting around that spot. Its black it looks like a relay/sensor. I bet you it has a crack in it or a wire pulled out of it. Ben

AZ TOM · 10-04-2012, 05:20 PM

Battery almost gone??

Wattner · 10-04-2012, 06:02 PM

Ground wire under the seat on top of the air box?

bomber1965 · 10-04-2012, 06:24 PM

Quote:

Originally Posted by jrsride2002

Bypassed safeties years ago.

~Junior

recheck them, they may have corroded or come loose.

jrsride2002 · 10-04-2012, 10:32 PM

Quote:

Originally Posted by Ben99r1

I had this happen to me. For me it was a relay located in the head light fairing/ shroud. I don't know what its called but take off the shroud and fallow the wires from starter switch down to where it meets the harness. It will be sitting around that spot. Its black it looks like a relay/sensor. I bet you it has a crack in it or a wire pulled out of it. Ben

Do you mean the turn signal relay? Or the diode?? The turn sig(stock) was the larger black one with two spade connectors. The diode is buried in a black boot with the turn signal connectors and cluster connectors and is noticeably smaller then the turn sig relay. Diode has never been fiddled around with.

Quote:

Originally Posted by AZ TOM

Battery almost gone??

Fresh and new. Not even half a season on it. Bought it in May-ish....

Quote:

Originally Posted by Wattner

Ground wire under the seat on top of the air box?

Though I doubt it, I havent confirmed just cause EVERYTHING else works just perfectly. So the sigs are grounded and the batt is grounded. Plus whatever else that ground right their.

Quote:

Originally Posted by bomber1965

recheck them, they may have corroded or come loose.

..............

....................

..... ..... Yer on............

Called my Uncle, said he'd be here tomorrow with his fluke. He's an electrician by trade, so I will also love to hear what he has to say.....

Thanks dudes for reading and helping!!!!!!

~Junior

jrsride2002 · 10-05-2012, 05:17 AM

Im an ass...... Really... Im just going to hang my head in shame... Such an idiot.....

OK so I honestly couldn't sleep over this issue. So here I was at 3:30am, chasing my wiring harness for loose connections, pinched wires, and checking my safeties..... After in depth review of the switch. They're 3 wires coming from it:
1.) To the relay in the battery box
2.) To the headlight High/Low beam switch
3.) To the headlight fuse
Turns out it was the headlight fuse.......I would have NEVER thought the starter button was based on the headlight fuse, seriously.... Here I knew I didn't know everything about this bike. But that to me is not 2+2=4.... Something else in my opinion...

Thanks for all the input guys!!!!

~Junior

P.S. How do I change the posting title to Solved??? I thought by editing the first post it would have done it, but no. I wrong again.....

Ben99r1 · 10-05-2012, 01:10 PM

HUH.. I would of not figured that either. Congrats on figuring it out.

XR650L_Dave · 10-05-2012, 02:27 PM

The schematic tells all

bomber1965 · 10-05-2012, 02:50 PM

Quote:

Originally Posted by jrsride2002

Working on it.......................Working on it........

All the fuses are in good shape....... Headlights(aftermarket) no issues.

Put Down the Wrenches and Step Away from the Keyboard!!

High Country Herb · 10-05-2012, 03:08 PM

Quote:

Originally Posted by jrsride2002

...I honestly couldn't sleep over this issue...So here I was at 3:30am, chasing my wiring harness for loose connections...

True dedicated adventurer...

jrsride2002 · 10-05-2012, 07:57 PM

Quote:

Originally Posted by bomber1965

Put Down the Wrenches and Step Away from the Keyboard!!

I have the Baja Designs dual Fuego lights

, which have their own fuse direct to the batt... Should've pointed that out.... oops

~Junior

10-04-2012, 03:28 PM	#1
jrsride2002 ^OP Adventurer Joined: Aug 2011 Location: San Diego, CA, USA Oddometer: 83	SOLVED: XR650L Not starting, no cranking OK, so I took a trail ride up in Yosemite. Woke up, rode for about 45 mins, I crashed. Brushed myself off, picked up the bike, fired up and continued on. I rode for about another 10 minutes when I stopped to verify if I was on the correct trail, via a map. I was, I hop on the bike, nothing. No cranking, no clicking from the relay(which I never heard before, but read about it). Bump started the bike, and everything was back to normal. I stop again for lunch. Eat, finish, jump on the bike, NOTHING Bumb started again, bailed out to camp, no stops, just made it to camp. Now im home, working on it....... Working on it.......................Working on it........ I pulled the seat, checked to wire to the start for breaks/cuts. Its good, a little wornout but shouldn't effect it yet. All the fuses are in good shape. Took a hammer and tapped the starter. The turn sigs work just fine in the garage. Headlights(aftermarket) no issues. My grounds look good. Bypassed safeties years ago. WHAT COULD IT BE?!?!?! Im at a total loss, please help, thanks, ~Junior __________________ '02 XR650L: Accerbis tank, motor mods, suspension mods, electronics mods '02 DR650: Yamaha Raptor 660 petcock, everything else stock jrsride2002 screwed with this post 10-05-2012 at 05:08 AM Reason: Solved

10-04-2012, 03:41 PM	#2
mcma111 Beastly Adventurer Joined: Jul 2007 Location: San Francisco,Ca. Oddometer: 8,011	Sounds like the right handle bar switch assembly. __________________ Steve in SF BMW's 58 R26 79 R100s 91 R100gs 87 Harley FXRS-SP ~ 06 KTM 625 SMC ~ 72 Honda CB750/915cc ~ 92 XR600/654cc ~ 95 XR650l/675cc ~ 03 CRF450r ~ 05 CRF450x ~ 02 XR650l/675cc ~ 86 YZ490 ~ 93 YZ80 ~ 93 XR650l Project

10-04-2012, 04:18 PM	#3
jrsride2002 ^OP Adventurer Joined: Aug 2011 Location: San Diego, CA, USA Oddometer: 83	I tested with a completely new/separate starter switch setup(I have a spare) ~Junior __________________ '02 XR650L: Accerbis tank, motor mods, suspension mods, electronics mods '02 DR650: Yamaha Raptor 660 petcock, everything else stock

10-04-2012, 04:21 PM	#4
smokeeater495 Studly Adventurer Joined: Oct 2008 Location: N.E. Indiana Oddometer: 503	Kick stand switch? __________________ Harley, been there done that. Don't want to be a pirate.

10-05-2012, 05:17 AM	#10
jrsride2002 ^OP Adventurer Joined: Aug 2011 Location: San Diego, CA, USA Oddometer: 83	Ok! I solved it!!! Im an ass...... Really... Im just going to hang my head in shame... Such an idiot..... OK so I honestly couldn't sleep over this issue. So here I was at 3:30am, chasing my wiring harness for loose connections, pinched wires, and checking my safeties..... After in depth review of the switch. They're 3 wires coming from it: 1.) To the relay in the battery box 2.) To the headlight High/Low beam switch 3.) To the headlight fuse Turns out it was the headlight fuse.......I would have NEVER thought the starter button was based on the headlight fuse, seriously.... Here I knew I didn't know everything about this bike. But that to me is not 2+2=4.... Something else in my opinion... Thanks for all the input guys!!!! ~Junior P.S. How do I change the posting title to Solved??? I thought by editing the first post it would have done it, but no. I wrong again..... __________________ '02 XR650L: Accerbis tank, motor mods, suspension mods, electronics mods '02 DR650: Yamaha Raptor 660 petcock, everything else stock

10-04-2012, 04:24 PM	#5
Ben99r1 Beastly Adventurer Joined: Mar 2006 Location: Pomona, Calif. Oddometer: 2,802	I had this happen to me. For me it was a relay located in the head light fairing/ shroud. I don't know what its called but take off the shroud and fallow the wires from starter switch down to where it meets the harness. It will be sitting around that spot. Its black it looks like a relay/sensor. I bet you it has a crack in it or a wire pulled out of it. Ben

10-04-2012, 05:20 PM	#6
AZ TOM Beastly Adventurer Joined: Oct 2008 Location: Prescott AZ Oddometer: 2,360	Battery almost gone??

10-04-2012, 06:02 PM	#7
Wattner Beastly Adventurer Joined: Oct 2003 Location: Ft. Lauderdale, Florida Oddometer: 2,765	Ground wire under the seat on top of the air box?

10-05-2012, 01:10 PM	#11
Ben99r1 Beastly Adventurer Joined: Mar 2006 Location: Pomona, Calif. Oddometer: 2,802	HUH.. I would of not figured that either. Congrats on figuring it out.

10-05-2012, 02:27 PM	#12
XR650L_Dave Beastly Adventurer Joined: Apr 2006 Location: Near Cortland NY Oddometer: 3,092	The schematic tells all __________________ ---->>Thanks for the rotor, guys!<<----

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