Boxerworks.com

Hi Guys,
Long time since I logged on, Still alive and well, I do have a small problem with the R90, When I hit the starter all it does is click like the battery is dead, but batt is full charged. Any thoughts?? I did rebuild the starter, I think last year, new brushes and a clean up.

Thanks Guys
Kelly in San Antonio

My first thought is you are dropping voltage somewhere.

How long has it been since you took a good look at your main starter cables, mostly the positive?

first easy test, is to pinch the positive cable (disconnect the ground at the battery, first) and see if you feel any crunchies under the insulation. If not, still cut the insulation back a couple of inches so you can pull it back and see if there is any corrosion going on. If not, put the insulation back and tape it up.

How old is your fully-charged battery?

I will check that Rob, Batt is less than 2 years old.

These bikes are known to have ground cable issues, so that would be my first guess. Of course, the easiest way to check a battery cable is to jump past it and see if it solves the problem. The down-side is that you have to have a cable to do it with. I've got some 3 gauge jumper cables I use for such tests.

And, of course, there's always the relay itself. That also can be jumped.

It is possible for a two year old battery to be bad. Having a battery load tested at a local auto parts store is free most of the time. Just to eliminate one possibility.

I've had this bike 30 years, and ever since I've had it there was always an issue with the starter, When I would hit the starter button it always had a hard time turning the motor over, like the batt was weak, but would finally spin it fast enough to get her going, that's why I took the starter out and cleaned it up, replaced the brushes (the old ones looked ok to me). But still the same problem. The first time last month after a battery charge is when it started clicking when I hit the switch, but would finally kick in. Now, after sitting a month, just clicks and wont engage at all. Pulling the tank today to have a look see.

Major, I have a set of cables as well, probably a dumb question but how do I jump the starter relay?

Do you have dirty starter switch contacts? Have you bypassed the switch?

Found the problem, it's the starter relay. quick test with a meter tells me its the contact to the solenoid. Jumped the relay and she came to life

Thanks for all the suggestions guys.
Kelly

Yay! Glad you figured out how to jump it. Easier to figure out (IMO) than to explain.

On The Road Again! (Isn't that a song )
I got a relay at Napa auto parts with the same terminals, 85,86,87,30 as the old one. It didn't have the 2 D+ ones but all that is is a connection point for the 2 blue wires. I spliced them together. Relay is smaller than the old one but worked like a charm. Just in case someone else needs to replace theirs it's a Napa AR274 Part #

Kelly