Hey,
Soooo I have a 1989 Honda CBR 600 f1 Hurricane that im rebuilding. I have replaced everything electrical on it except the voltage regulator, the handle bar switches and the horn(works fine). All my signals work, headlights work, but im having problems with getting power to my starter. I have power to the silinoid (sp? sry) but not to the starter, every time i push the start button nothing happens..no clicking.. nothing. Its a wiring harness from a 1990 bike that was running, same with the computer and ignitions coils...idk if that makes a difference or not but.. got any ideas of whats going on? again i havent replaced the handle bar switches but i know the left side works and its a new ignition switch but idk on the right side with the starter button an kill switch.... ideas??? pointers????

Thanks Guys!!!!!

 

I don't have a wiring diagram for a 1990. However, most of these bikes work the same. The starter button provides power to a large relay by the battery. When the relay turns on, then power is applied to the starter. If you don't hear any clicking, then you're probably not turning on or energizing the starter relay. This could be a bad starter switch, a poor connection, or even that the starter relay has been connected wrong (since you indicate it's not the right wiring harness). How are your skills with a meter ? Do you have a meter, or know someone with one that knows how to use it ?

 

First off, thank you for the reply! Second if you mean the silinoid when you say starter relay then I think I have power to that. I dont have a voltage meter that shows how much power is getting to it but I do have one that shows if its getting power at all. I attached three photos showing me testing it all for you. Its a new battery and the starter relay( i was told) came off a working bike.. same with the starter.. ? :/ idk... if you think its either that or the switch then im guessing the switch is gone? What do you think? oh and the only thing different between the wiring harnesses of the 1990 and 1989 bikes that i can see is the computer which i bought a new one of. I also attached two photos of the wiring harness diagram.. i hope you can see it well enough. Get back to me and tell me what your thinking
Thank You!!!!!!
Dylan

 

OK, here is what I see. Thanks for the photos, that does help and yes I can see the wiring diagram well enough to read it. Good job.

In the first photo, you're showing that your battery has power and that's good. In the second, your're showing that if you connect across from one side of the Solinoid ( in this case it's really a relay) to the other you have power as well. If the relay (solinoid) were being told to turn on, then the starter would probably be turning. You will always see battery voltage across those contacts even with the ignition key turned off.

That relay (solinoid) has 2 smaller wires going to it, a Green/Red and a Yellow/Red. You need to see if you're getting power to the Yellow/Red wire when you actually press the Start switch. I suspect that you're not, but you need to test to be sure. Leave your testor attached to the - terminal of the battery, and the probe end try to attach it to the Yellow/Red wire. The probe should light up when you hit the starter button.

Let me know what you find.

 

Sweet, Im glad that all worked out, and thank you again for the help on this.

soo you were right, im pretty sure. I tested the connection while pushing the button on the relay and there was no power. Then I did what you said an had one side connected to the battery and one to the red/yellow wire on the relay and there was a connection when I pushed the start button. Ill attach a photo showing where I checked for power on the relay the first time. It is showing that there was no power. The second photo is showing it working with it attached to the battery and the relay. I dont know what this means now? Is the relay messed up? or the switch? or what haha

Thanks again bro

-Dylan

 

OK now, I need to get some clarification on exactly how you made the test. In the first photo it appears that you're checking between the Green/Red wire and the Yellow/Red wire. I would not expect to see anything here except for when you press the starter button.

I realize it may seem a little **** here, but I need for you to explain this step more clearly. You said:

"Then I did what you said an had one side connected to the battery and one to the red/yellow wire on the relay and there was a connection when I pushed the start button. "

What terminal on the battery were you attached to ? The Positive or Negative terminal ? And what do you mean there was a connection I pushed the start button.

I looked at your photo's more closely and it looks like you were on the Green/Red wire and the Negative terminal of the battery. If you were pressing the Starter button at that time and the probe lit up, that indicates a couple of things. The Starter button is good as is the wiring up to and through the Starter Relay (Solinoid). This also indicates that you don't have a ground for this circuit. The Green/Red wire is the ground side of the Starter Relay. Ground is provided by a couple of things. If you're in Neutral, you'll have a ground provided there. If your Clutch Lever is pulled in and your Side Stand is in the Up position, you'll get a ground there. You're going to need to trace the path of the Green/Red wire.

 

Its totally fine, here are some better photos. I did a test between the red/yellow wire and the green/red wire and even after pushing the start button nothing happens. I got the volt tester to light up when I had one side attached to the negative battery terminal and the other attached to the red/yellow wire. It would light up only when I pushed the start button. Did that clarify it or should I try that again lol

So i dont totally understand what your saying about tracing back the wires? and the kickstand and neutral? could you try explaining that again for me. Sorry. Im just trying to understand. and when I trace back the wire what am I looking for? should I be testing or ... what hah what is it thats likely causing the power to not get to the starter? or have we gotten to that part yet?

 

You're getting close. If you look at the wiring diagram below, you see in the top right corner is the Start Relay. The two wires coming out the bottom (there is actually 4 wires, but we're not interested in the other 2) are the G/R and the Y/R. In order for that Relay to Energize, you need a supply voltage and a ground. The Y/R wire is the supply and you verified that it's getting power when you press the Start button. If you follow the line it goes down and splits in two directions. Following it down, it goes through a Silicone Rectifier and then onto the Neutral Switch where it reaches Ground. So on your bike, you need to locate the Silicone Rectifier device to see if it's connected to the Y/R wire on one side and then a LightGreen/Red wire on the other side then going over to the Neutral Switch.


Basically we're looking for a connector that's not connected, or a cut or broken wire. Look for damage to the wiring harness. This is not going to be a problem of the wire being shorted out. It's going to be either a loose connection on something or maybe a bad switch. I'm betting on something not being plugged in. Since the wiring harness is from another bike, something is probably not plugged in. You'll need to look in your manual to find the location of that Silicone Rectifier to check it's connections.

You're doing good. You're making progress and we're eliminating things. Let the hunt begin.

 

I think I found the Silicon Rectifier? Its in the photos and the wire colors fit other that it also has two light green wires going to is as well. I'm guessing that they are ground wires? Either way there is no power at that point,(the silicon rectifier) you were right! So I took apart the wiring harness. I followed the Red/Green Wire up the harness from the Silicon Rectifier to a second point of connection (also in the photos as "power up the line"), I tested there and had power when I pushed the start button but not at the silicon rectifier when I pushed the start button? So I followed the other wire coming off the silicon rectifier down the harness the other way and its ends at a green plug and its not connected to anything? I don't understand how there is power up the line on the same wire but not down the line on the same wire? Got any ideas.. and When I took apart the harness there were multiple points where the wires were crimped together and taped. I don't know if that's how its should be or not and weather that would effect anything. The colors of the crimped wires are the same and have a good connection but I thought I would ask. I put in photos. There is a photo of the plug I'm talking about..I don't know what It goes to? It has six (6) wires on it and they are...

Yellow/Green
Blue/Green
Orange
Blue
Blue/Red
Light Green/Red

Do you think this plug could be the problem?

Let me know what your thinking!

-Dylan

 

other three photos