Ok guys, i need some help with my custom build. I started about two years ago with a stock -99 with 34.000 km on it. Building it my own way, stripped down as a fighter/stunt bike. Even though i dont stunt much.... i just like the looks and its my build.
Anyway... started ripping apart everything when i found out all the wiring for dirtbike-style handlebars was too short! Figured i could make my own harness... Stupid idea! Im pretty good at building bikes, but not so great at electrical stuff. And since i have mostly built bikes based on pre modern ignition, anti-theft etc im kind of stuck.

So here is what i did when i recently got back to the process after a year of stand-still.
* Bought a new (used) stock main wiring harness and put in place, plugged in all connectors. All relays are still connected to stock harness (even though i dont need all when using mo.unit, will eliminate later..).
* Stock switch housings are NOT mounted/connected
* Using a Motogadget mo.unit + mo.switch pro to control ignition(power on/off) switching + rear/front + blinker lights, horn, start/stop/kill.
* HISS connected to stock harness. Removed the ring/transmitter from the stok ignition lock, and strip-tied the stock key ro the ring for now. Should be enough for the key/ecu to operate (using bikes stock ecu and key).

I can now control igntion on/off, start and lights from the mo.unit and mo.switch.
Starter will turn, i have lights and and also the stock instrumenst will turn on - and i get a green light on the key.
No start....
Fuel pump did not run. Hot-wired directly to battery to test, and its running/priming fuel. Still no start.
Since the pump is connected to stock harness with stock connector - not working. And still no start after fuel is primed - i suspect it must have something to do with the switch housings? Is there something in there that has to do with grouding that i must sort out?

Unfortunate for me my eyes are getting older....and im having a real hard time to read the printed wiring diagram in low-res A4 format (all black and white).
Need some motiviation to troubleshoot and how to proceed ........ thanks in advance for any help

 

Just connected the stock right switch housing (kill, start), gave it a litte bit of fuel. No start.... How much fuel will it actually need just to get it fired (not run)? i just filled a couple of "fuelfilters".... so not much.
But at least now i hear the fuel pump starting.
Clutch switch - i dont have the stock clutch lever, but it should start anyway as long as the bike is in neutral right? Or should i jump the wires?

The only wires not connected right now is the clutch switch and fuel level.