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Old 05-25-2013, 10:19 PM   #1
Big_John OP
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2004 950 Start Problem

I need some advice. About a week ago, I start the bike....and ride her in town, running errands...starting and stoping the bike several times. Then I pull up to the house, turn her off......then decide to start her and ride into the garage. The starter button isn't working. The key is on and all electronics seem fine....but no starter turning over. I jimmy the key on and off, flip switches.....flip the side stand up and down......nothing. Then, out of the blue it starts.

Couple of days of riding around town.....no issues.

Then I go out with some guys, running dirt roads.....and after an hour of riding with a half dozen starts.....it goes dead. I mean....It won't start. Yeah, we can bump start the bike and it runs great.

The magic button doesn't work.

We took the, starter button switch apart and tried to jump the switch.....but nothing.

I bump started her and rode home.

Any ideas?



.......
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Old 05-26-2013, 12:02 AM   #2
gefr
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Maybe the solenoid has the external contact corroded?

Could be this?
#60011058000 at the battery box group.

 photo pyns_corroded_starter_relay_zps9d3aada4.jpg

 photo IMG_63351600x1200_zps59bad60d.jpg

Often gets the external brass connection corroded and broken.


Cheers.

gefr screwed with this post 05-26-2013 at 12:23 AM
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Old 05-26-2013, 06:51 AM   #3
Big_John OP
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Got a wedding today, but am off on Monday and will tear into her.

This connections on the solenoid will be the first thing I check.


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Old 05-26-2013, 10:45 AM   #4
GoNOW
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The starter solenoid is sold as an aftermarket item from Parts Unlimited. Cheaper then the KTM one and most dealers can get it next day.
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Old 05-26-2013, 11:00 PM   #5
jwalters
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Side stand switch? Probably not if you were able to bump start it, but could be intermittent.
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Old 05-27-2013, 09:19 AM   #6
Big_John OP
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Have the bike's skid plated dropped and checked out the solenoid. The connections are beautiful.....nearly new looking and the fuse is just fine.

When I turn on the key all the electronics seem to work just fine and as I stated earlier, it easily bump starts and runs great.

Any other ideas?

Is there a way to place a screw driver across two connections and start?



Does the 950 have a switch, requiring the clutch to be pulled in? But I guess if it runs on bump starting....then I don't have a safety switch problem.


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Old 05-27-2013, 04:42 PM   #7
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Took the bike over to a mechanic friend and we started to check wires for current. The solenoid is getting juice, as are the kill and starter switches. The bike will start right up, if we jump the two circuits between the two red wires on the solenoid.....so the starter and wiring to the starter is just fine.

Supposedly there is a starter relay somewhere in the cowling, so our guess at this point is a bad solenoid or the starter relay in the cowling is bad.

Anyone encountered such things.......and have advice?


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Old 05-27-2013, 05:01 PM   #8
renogeorge
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There is a starter relay. I don't know location for an Adventure. It will connect the battery cable from the battery+ to the heavy cable to the starter. The push button sends 12 volts to the relay which closes the relay and completes the circuit from the battery to the starter. Check for 12 volts at the relay when the button is pushed. Note that there is a small terminal at the relay which has 12 volts all the time. It feeds the ignition switch, accessories and all electrical other than the starter. It also sends 12 volts to the starter button. Test for that 1 first. Then for the switched position. Could be button or relay or wiring in between.

Good luck
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Old 05-27-2013, 11:35 PM   #9
gefr
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The starter relay is the one in the photo. This connects the battery to the starter.

Mine died at 40k kms. It was sounding normal, clicking but no contact was made.
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Old 05-28-2013, 09:45 AM   #10
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I don't get any clicking down at the solenoid. The only clicking I notice is the clutch switch on the actuator up under the top of the cowling.

Should this tell me something?


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Old 05-28-2013, 10:05 AM   #11
renogeorge
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Not sure I am following you. I would do my starting in neutral and leave the clutch out of it. When you said that you shorted across the 2 red wires of the solenoid, did you mean the relay--the piece pictured in GEFR's photos? That relay has 3 small connections:

1. Ground
2. + to ignition, lights and starter button (Hot all the time)
3. + back from starter button to close relay (Hot only when button pushed--if not button or wiring is bad)

And 2 heavy duty battery cable connections:

4. From battery (hot all the time)
5. To starter (hot when button pushed and relay closes)

Jumping across 4 and 5 should start. If not problem is in starter or solenoid.

If 3 is hot with button pushed and jumping 4 and 5 starts, relay is bad.

Hope that helps
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Old 05-28-2013, 12:20 PM   #12
Big_John OP
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Quote:
Originally Posted by renogeorge View Post
Not sure I am following you. I would do my starting in neutral and leave the clutch out of it. When you said that you shorted across the 2 red wires of the solenoid, did you mean the relay--the piece pictured in GEFR's photos? That relay has 3 small connections:

1. Ground
2. + to ignition, lights and starter button (Hot all the time)
3. + back from starter button to close relay (Hot only when button pushed--if not button or wiring is bad)

And 2 heavy duty battery cable connections:

4. From battery (hot all the time)
5. To starter (hot when button pushed and relay closes)

Jumping across 4 and 5 should start. If not problem is in starter or solenoid.

If 3 is hot with button pushed and jumping 4 and 5 starts, relay is bad.

Hope that helps



This really helps, as the relay has been suspect all along.

Can anyone help with the part #......as I want to make sure I order correctly.

Thanks,
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Old 05-28-2013, 12:43 PM   #13
renogeorge
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60011058000 Appears to be the same as used on the KTM single cylinder dirt bikes. It is located on the side of the battery box.
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Old 05-28-2013, 01:51 PM   #14
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Have a look at the parts fische...

http://www.munnracing.com/

go to the battery case #1

Cheers
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Old 05-29-2013, 06:07 AM   #15
Big_John OP
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Quote:
Originally Posted by gefr View Post
http://www.munnracing.com/

go to the battery case #1

Cheers
There are two starter relays behind the instrument panel, inside the cowling. If you bend down by the front wheel and look up toward the handle bars, you can see both of them on the right side (or left side if you were sitting on the bike).

Both relays have the same part number: 58411057000. And they retail for $19.95 each.

I wonder if anyone can explain to me a few questions?

1. What is each relay responsible for? One on the right? One on the left?

2. How do I test if one or both of them are bad? (I have heard guys explain that I jump circuits, but since these guys have multiple wires involved, I don't know how to do that.)

3. I have also heard guys talk about exchanging or switching the two relays. I am not sure what this will accomplish if one or both are bad.

4. I also had someone tell me to get a test meter (which I have) and do an Ohm test on the circuit. How do I do this and will this test tell me where my problem is?

Sorry for these questions, but I struggle understanding electricity.
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