Bike won't start! (Dodgy electrics)

meyrick · Scooby Slapper Joined: 05 Dec 2004 Karma :

Landed myself in it a bit with the CB125TDJ. I replaced the headlight with a halogen unit via a pair of relays and an inline fuse and fitted a switch for the heated vest on the handlebars. Both work perfectly but now the bloody bike won't start! Evil or Very Mad

Here are the facts:

I labelled all the connectors inside the headlight before I took the old one off so I know everything is back where it should be - I have checked 1000 times.

All the fuses are accounted for.

The battery is fully charged and putting out >12V.

The bike is in neutral and/or the clutch is pulled in.

The starter solenoid is fine, although it is not receiving any power at all when the starter button is pressed.

When I turn off the ignition and short the starter solenoid contacts the motor turns over, but when I turn on the ignition and do the same nothing happens.

Everything else on the bike is working including brake lights, indicators, headlight, horn etc.

It's driving me MAD. Have I missed something? Any help will be very much appreciated. Very Happy

BFG · Brolly Dolly Joined: 14 Feb 2005 Karma :

Will it bump start?

The start button usually just short to earth and the hadlebars. This might help when testing

meyrick · Scooby Slapper Joined: 05 Dec 2004 Karma :

Oooh, interesting. Not sure. Never bump started a bike to be honest. I could give it a go.

musclebiker · Nova Slayer Joined: 21 Mar 2005 Karma :

Yeah just get a buddy to push, hold the clutch in, slip it into 2nd and then let the clutch out sharply. That should at least get the bike going. (Enough to get it down to a dealer.)
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Stupidity is unbeatable, but that doesn't mean we should give up fighting it.

Jayman · Derestricted Danger Joined: 07 Apr 2005 Karma :

Or i know it sounds obvious but try checking your battery fluid level, shouldnt thing it would be a dry cell on a cb125 so check the fluid level. Its not much to buy and could be the problem. Also, batteries tend to lose charge, so the bulb could be draining it slightly. Bump starting the bike and giving it a good run should recharge the battery somewhat if this is the problem. Good look mate. Thumbs Up

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'Yes, of course! We can't crush a mutiny here, only to return home and find everyone wearing overalls and breaking wind in the palaces of the mighty!'

BFG · Brolly Dolly Joined: 14 Feb 2005 Karma :

meyrick · Scooby Slapper Joined: 05 Dec 2004 Karma :

meyrick · Scooby Slapper Joined: 05 Dec 2004 Karma :

Just went into the garage to check the rectifier and the starter switch with a multimeter. I had to bend the pins on the starter switch connection box to get the multimeter pins in there and hey presto, the bike now starts. A valuable lesson learned: just because everything is plugged into the right socket doesn't mean there isn't a loose connection! Doh!

Well, thanks guys, mystery solved and I don't have to give the evil bus driver another penny Thumbs Up