Stop start switch

[Bigtrks]

Dropbox

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You can read a bunch of stuff about your bike with this manual. In the meantime troubleshoot your problem so you can concentrate on fixing it or just living with it.

So does that mean don’t ask so? Damn, any questions?

 

[Rottweiler]

Look at other years also the 2004 doesn't go into as much detail the later years.

Dropbox

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[Bigtrks]

If I'm not mistaken, you have started different threads for the same issue (intermittent start from the control switch). I can't sort that out but give this a try with the bike in neutral. First , pull the green wire off the starter solenoid. Second , put a meter to ground on the connector. Third, turn the key on and hit run then start. You should get 12vdc on the green wire along with hearing the click from the Compression Releases. Repeat a bunch of times because you have an intermittent problem. When it fails I suspect you will hear the click from the CR's but not get the 12 vdc on the wire. If you do it 10 times and always get the 12vdc and the click, your issue is most likely with the Solenoid.
If you get the intermittent failure (no 12vdc ) your issue is with the EHC and not the Solenoid. If this is the case pull the connectors off the EHC looking for a loose or backed out wire then replace the Dielectric grease and put it all back together.
Come back with your findings and avoid starting new threads because it makes it difficult to help you.

Ok I pulled the green wire pressed start a couple dozen times .. I won’t have a volt meter until morning . But the only noise I hear is the cr on the front head cannt hear on feel anything from the rear is that normal??

 

[Bigtrks]

If I'm not mistaken, you have started different threads for the same issue (intermittent start from the control switch). I can't sort that out but give this a try with the bike in neutral. First , pull the green wire off the starter solenoid. Second , put a meter to ground on the connector. Third, turn the key on and hit run then start. You should get 12vdc on the green wire along with hearing the click from the Compression Releases. Repeat a bunch of times because you have an intermittent problem. When it fails I suspect you will hear the click from the CR's but not get the 12 vdc on the wire. If you do it 10 times and always get the 12vdc and the click, your issue is most likely with the Solenoid.
If you get the intermittent failure (no 12vdc ) your issue is with the EHC and not the Solenoid. If this is the case pull the connectors off the EHC looking for a loose or backed out wire then replace the Dielectric grease and put it all back together.
Come back with your findings and avoid starting new threads because it makes it difficult to help you.

Never mind I finally found the old friend. They should both be doing it.

 

[Mikeinjersey]

Ok I pulled the green wire pressed start a couple dozen times .. I won’t have a volt meter until morning . But the only noise I hear is the cr on the front head cannt hear on feel anything from the rear is that normal??

Yes it is normal for the cr to click but with the wire disconnected you won't hear anything down by the solenoid. When you get your meter set the dial to the scale marked DCV to 20 . Disconnect the green wire and put the red lead to the end of the green wire and the black lead on any ground or even back to the battery - side. Now that it's hooked up whenever you hit start and hear the CR's click you should also see the 12vdc. If you get both (click and 12vdc) every time it would indicate that your EHC is working properly and your Solenoid is the problem.
Let us know what you come up with.

 

[Bigtrks]

Yes it is normal for the cr to click but with the wire disconnected you won't hear anything down by the solenoid. When you get your meter set the dial to the scale marked DCV to 20 . Disconnect the green wire and put the red lead to the end of the green wire and the black lead on any ground or even back to the battery - side. Now that it's hooked up whenever you hit start and hear the CR's click you should also see the 12vdc. If you get both (click and 12vdc) every time it would indicate that your EHC is working properly and your Solenoid is the problem.
Let us know what you come up with.

Ok thanks when I checked the cr’s on y the front one clicks even if you touch it while pushing the button only one has sound or movement so I guess I just reached down to Wire and make sure it’s all hooked up

 

[Mikeinjersey]

If your rear CR is not working that will be it's own separate issue. Do a search for CR replacement and I'm sure you will find several threads on the subject.
As long as you hear at least one CR working we know the EHC is doing it's job and we just need to verify the voltage to the starter solenoid is 100% or not.

 

[Bigtrks]

If your rear CR is not working that will be it's own separate issue. Do a search for CR replacement and I'm sure you will find several threads on the subject.
As long as you hear at least one CR working we know the EHC is doing it's job and we just need to verify the voltage to the starter solenoid is 100% or not.

Thanks for all the help .. I’ve never tried push on a cr but I just tried and just a slight touch and you can push it down and won’t come back up until started what ever that means . Riding to my sons house tomorrow hopefully he can figure it out .. he’s pretty good for a son-in-law lol

 

[Big Ted]

That wire goes to the brake sensor. The magnet is in the brake lever. The set screw is located just below the sensor. When you put the new sensor in, turn the key on, then pull the brake lever until you feel pressure. Slide the sensor in until the brake lights come on. Then tighten the set screw.
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Thanks. That post came in super handy this evening. Would have saved myself a ton of time had I thought to check here earlier.