You need to look at wiring diagram and understand how starter circuit works. Starter solenoid is activated by starter-relay inside junction box. Starter-relay's activation coil is powered by +12v coming from battery going through series of switches: ign-switch, run/stop (kill switch), start button. Ground side of starter-relay's activation coil is connected to chassis-ground through series of safety-interlock switches: clutch-switch, neutral switch, kickstand switch. Any one of these switchs being in incorrect state will prevent starting. To find problem, you need to take measurements at every stage of circut:
Start at beginning and trace electricity flow using wiring diagram. Measure +12v POWER side of circuit. Measure at EVERY segment all the way to starter. Where power stops will home in on problem area.
1. Do you have power at battery? What is voltage?
2. Do you have power going out of starter-solenoid going towards ignition switch? What is this voltage?
3. Do you have power going into ignition switch? What is voltage?
- ignition-switch ON from this point
4. Do you have power going out of igniton switch? What is voltage?
5. Do you have power going into kill-switch? What is voltage?
6. Do you have power going into start button? What is voltage?
- press START button for following tests
7. Do you have power going out of start button? What is voltage?
8. Do you have power going into junction box to starter-relay? What is voltage?
9. Do you have power going out of starter-relay? What is this voltage?
10. Do you have power going into starter solenoid? What is this voltage?
Similarly, you have to measure GROUND side of starting circuit. Also need to verify these ground readings at wires going into junction box to test wiring in between as well.
11. What is resistance (ohms) between battery's negative terminal and starter's ground terminal?
12. What is resistance between clutch-switch's black+black/red wires when clutch is squeezed? That's green+yellow/green on harness side
13. What is resistance between kickstand-switch terminals when up?
14. What is resistance between neutral-switch and chassis ground?
15. What is resistance between junction-box's yellow/green wire and chassis ground?
Basically, you want to measure, BUT MAKE NO CHANGES to circuits, in order to narrow down to specific switch, wire segment or connector that is causing your no-start condition. If you mess with system, you make changes that will introduce a 2nd or 3rd fault in system and it'll get even more difficult to troubleshoot. You need to find the problem 1st through non-invasive testing, then it's simple to fix. Again, only 30-minutes or less to do properly with permanent solution.
Last edited by DannoXYZ; 8-9-2019 at 3:49 AM.