Looking for some ideas.

I have wrenched on cars a bit, but not failure with bikes.

My Alternator cover was leaking oil and was getting worse. After being dogged be a guy at a bike show a few weeks ago about how it leaked oil like a Harley I decided I was going to replace the gasket.

Well that went well; or so I thought.
- I got the cover off, removed the alternator coil
- Clean up the cover real good re-installed the coil.
- Put gasket sealer and gasket on the cover and bolted it back on.
- Replaced the center headlight bulb.
- Turn the key/hit the button and it won’t start.

Battery is good and the relay clicks on when attesting to started, but nothing.
The headlight/cluster pnl goes out when I hit the start button

I am just looking at were to start on this. It is probably something stupid.

 

Retrace your steps. Did you forget to/did a wire come loose inside the cover when reassembled?

Not sure from your post; does the bike turn over?

 

Well, you didn't do anything with wiring, and the alternator (stator) isn't necessary for starting the bike, and if you are ABSOLUTELY 100% POSITIVE the battery is FULLY-CHARGED, then your problem is most likelly not electrical.

Obviously, you should throw your battery on the charger overnight.

If that doesn't do it, then I bet you didn't reinstall the coil properly, or there's something stuck in there, which is causing it to jam, which isn't allowing the engine to crank. Once you get it all working, do a voltage test on the stator, and the rest of your charging system regardless.

 

Is your fuel pump priming? If you havent learned these bikes are very tempramental towards battery voltage. Like Johny said (if your fuel pump is priming) start at the simpleist thing that being your battery. I highly doubt anything in your stator side would case the bike not to crank. Now on top of that cover where the starter is check your connections, maybe a bolt at the starter came lose such as the ground....

 

I put the charger on over night to asure the battery was good.
Connected it to my quad and it fired right up....battery is good.

Fuel Pump is priming, but it won't turn over.
What electrical I hav echeck so far, wasn't loose or disconnected.

I havn't had any real time to back track and trouble shoot, but have set Sunday aside to get working on it.

These are great tips on were to start looking.
I haven't had this bike for long: about 5mnths newer, so I know very little about them.

Before this I had a 500 interceptor in Highschool that my father did the wrenching on and like most highschool kids didn't pay much attention....heck even if I did it has been so long now I probably wouldn't remember anyhow......


Well I post what I find Sunday evening.

Thanks agian.

 

I really gotta lean towards the jammed stator idea.

 

Yep jammed Stator Idle Gear was the culprate. The connecter for the rectifier and the stator conect to gether is also fried.Parts are ordered.........should be back on the road soon........definatly not like working on a car, but alot more fun to work on. love the fact that you aren't so cramped in a 2car garage....

 

All is half arsed well in my world once more.
We are back on the road as of today......Oh how I missed riding.

Thank you all for your help, ideas and support. It is always greatly appreciated.