Key gives me lights but nothing else

[G-Gaurd]

Hi
I charged up my battery and then turned on the key I get the tail lights,horn,turn signals ,oil and neutral lights but nothing else . When I first turned on the key everything was fine starter kicked over then I reached over to turn on the gas and then there was nothing ... I took cover off of the ignition switch and cleaned all contacts.... Checked all my fuses and there good ... When I pulled a plug to see if there is spark but there is not when I kick it by foot
What would cause the starter button and prevent spark at the plugs ? .... I've never used the on/off switch above the starter button and I don't want to dump a bunch of money I don't have replacing the whole electrical system one item at a time

Any help would be appreciated .... Can I test the starter switch or the on/off switch with voltmeter or test lights ?

 

[arfstrom]

as long as your troubleshooting, use your car/truck, (as long as it is not running) jump your battery. (shouldn't need to kick with jumper cables, (I don't remember trying to kick with cables)

make sure your handlebars haven't been freshly painted/coated with something that will prevent energy return to the battery to complete the starter/other circuit with the off/on/off.

Ohh, yea, last time I had this problem, I had to go into the headlight bucket, and pull the ignition connector apart, and put it back together.

 

[G-Gaurd]

Ok ... I'm into the headlight bucket and pulled that one apart also .... I'm not getting anything from the starter button but I have jumped the starter solonoid and the starter does work but I'm getting no spark at the plugs .
Would a bad condenser cause any of this ?

I unhook battery charger... Turned on key ..... Hit starter button .... It worked .... Reached over and turned on gas .... Hit starter button .... Nothing

 

[Maxim-umm]

How old is the battery? I had a similar issue with my original battery, bought a new one and it sparked every time after a charge and install. Turns out my original would charge, but couldn't hold enough to give me much more than one or two cranks

 

[G-Gaurd]

It's not the battery

I turn on the key and I get power everywhere ... I get power at all the fuses except one ... The fuse with the R/W wire ... In fact I get no power any where on that wire ... From the start switch to the fuse box my R/W wire has no power running through it ... I'm gonna have to run down my entire harness and find where I'm sure I got a bad relay or contact breaker that's not passing the voltage to that one wire

Gonna pull the battery box out

And it's gonna be over 100 ° tomorrow

 

[xschris]

What model/year bike do you have? Post some pics of it. This will help people a lot in trying to figure it out. The 81-82 sohc xs400 has a safety relay for the ignition.

 

[G-Gaurd]

1980 XS 400 special. ..... 9 / 80 is the manufacturing date
I replaced the plastic fuse box with 4 individual blade type fuse holder cause the one in it was all dried out and fell apart.
I traced the R/W wire and it seems to start from under the battery box .... I feel today is gonna be great ... I'm gonna be losing a lot of water weight .... Lol

Here are some photos

 

[G-Gaurd]

A few more photos

 

[xschris]

The bike is a 81 SH with that manufacture date. It should have a 4R4 vin code. There are two relays behind the carbs attached to the frame. One is for the head light and the other is the ignition safety relay. Using crimp connectors is a bad idea. Solder them and then shrink wrap.

 

[G-Gaurd]

I know the relay your talking about .... Is the left or the right the shut off relay ? .... Can I test the relay to see if it's good or bad ?

 

[xschris]

No testing for the relay. Check the wiring diagram for the color of wires that goes to it. On my two bikes that use this setup they are on separate sides from each other so I don't know what stock would be.

 

[G-Gaurd]

The shut off relay is on the left .... According to manual I removed relay and with jumpers put power to it and got the clicking sound .

I put my battery back in the bike and turned on the key and with a test light I started touching the plug and there is still no power getting to the relay.. I then started on doing the connector to the voltage regulator .. I get light when I touch the red wire on the plug ... Would I get light if I touch any other wire on the plug of the voltage regulator ? ... Even if I turn on the ignition switch ? ... Manual says I should use the multimeter ... Actually use 2 multimeters and test when running .... What ? ... Can't get it running ... Lol

 

[BBS360]

Check out the wiring diagram for clues. The voltage regulator is not involved in the function of the relay.
You'll want to check out the clutch switch, neutral switch, kill switch, starter switch, and starter relay.

 

[arfstrom]

Dont use the Left/right orientation for knowing which relay is which,use the wire colors from the wire diagram.
I was able to swap my relays, with no detrimental issues, I have since put them back. my goal was different than yours thou. (I was worried about the headlight) If your this deep, I would print out the color diagram, and go though each wire looking for continuity between ends. with a focus on the starter/operations side of the items. ie safety relay to oil sensor, neutral sensor, small wires on the starter solenoid, off/on/off switch, power on either side of the fuse, and to the next item in the wire path to the starter... (sorry I was going by memory)

 

[G-Gaurd]

I took a Gamble and decided to jump a wire to the safety relay and it clicked .... I pushed the start button and it engaged and turned over but still no spark ... So it feels like it's in the regulator .... ignitor..... And ignition unit .... Neutral switch is good oil switch is good .... Looking at the ignition unit I gently poped it open and there seems to be some kind of caramel glue on the circuit board that's kind of sticky .... Might be some kind of insulating resin so I've left it alone ... But still have no power going to the R/W wire ... That's the one I need to track down

 

[BBS360]

I wouldn't tamper with the ignition unit too much. It isn't the source of power on that wire.

Maybe start with the fuses, fuse holders, work forward to the kill switch, and back again.

 

[G-Gaurd]

The fuses are all. Rand new and I replaced the fuse holder with brand new blade style fuse holder .

Shouldn't there be power going to the ignition unit when I turn on the key ?

I literally took a wire and touched a connector on the shut off relay and touched the electric start button and it turned over fine
So I figure I can scratch the starter relay starter button shut off relay ignition switch and I tested the start stop switch for continuity in the on and off position and meter checked out ....

I'll be at it again when I'm off work

 

[BBS360]

Does it have voltage at the fuse box? At this point I'd go in order, following the wiring diagram, starting at the fuse box (assuming voltage is present there), and working your way along the wire until you lose voltage.
Could be a bad connector or something hidden in the wiring harness.

 

[G-Gaurd]

I get power to all the fuses except the R/W wire .... I'm probably gonna pull the wrapping off the harness and go for the whole can of worms thing

 

[xschris]

Have you pulled apart the start-run switch?