Topic: 400F starter motor troubleshooting

[jakec]

My 400 starter motor stopped working. I have already rebuilt the switch with the 3D printed housing, and it's working (turning off the headlight when you press the button). All my other connections are clean and connected too (yellow/red and green/red). I traced them all over the bike and checked them. I also bench tested the motor out of the bike and it's working. Finally, I just jumped the green/red wire from the solenoid directly to the frame grounding point for the battery. Still nothing, and the solenoid isn't making any noises either. Does this mean the solenoid is bad? I can't think of anything else.

[jakec]

I should say the bike runs, I just have to kick it. Oh, and I have jumped the posts on the solenoid and it did turn over. But like I was saying, all the yellow/red wires are connected, and that would be the likely culprit right..

[bryanj]

Try testing the solenoid by putting both small wires one to each side of battery, if no click solenoid duff if it clicks wiring duff

[jakec]

Ok I just left the green/red wire plugged in normally and jumped the yellow/red straight to the battery and it turned over. So that means the yellow/red is causing a problem somewhere, if I'm following along

[jakec]

There are only the two locations where the yellow/red has a connection, right next to the solenoid and then under the tank where the end of the handlebar switch leads are. Both are clean and connected. And I have the switch pod opened up and I'm looking down at the switch housing and it looks perfect..

I jumped the wire in that area to the battery and it turned over (eliminating switch pod). So I guess it is that switch. The button has already been rebuilt with the 3D printed housing, and it worked for a while before it stopped working.

[jakec]

I took the switch apart and nothing looks wrong with it. And it was still doing its function of turning the headlight off. So I guess there must be a break in the wiring somewhere, maybe inside the handlebars. But its all still in its factory black sheathing.

[bryanj]

either the switch is corroded or the wire broken between switch and tank

[jakec]

Yeah the switch is totally perfect inside and out, so it must be a broken wire. Kinda considering putting a switch somewhere else maybe, idk. I don't want to disturb the black sheathing tracking it down. Not to mention taking apart the handlebars and pulling the wires.

[bryanj]

Test for power with switch pushed at either end of the wire