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Discussion Starter #1
2005 C50 won't turn over. Pump comes on, clutch in, kill switch off, neutral light on and headlight dims when hitting start. Happened before and mysteriously went away.... had to push start it in 5th.

Thinking about bypassing the relay with some heavy gauge but can't see where to go to the starter.

Any suggestions appreciated. Have a Clymer but haven't really studied it yet.

John K
 

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I'd just try charging the battery. I'm guessing this was probly your first time trying to ride this year Since winter hit. Yesterday I went to start up my c50. The lights and accesories worked fine but the bike wold not turn over. I decided to try and charge the battery before I looked into anyting. It turned out my bike had a low charge.
 

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Yeh I bet its the battery or the conections. I had that trouble on my 07 and I cleaned the terminals and all is well.
 

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Discussion Starter #5
Fully charged the battery. No change. Can start the bike fine by jumping from the battery to the starter cable connection on the relay.

Removed the relay... got 4.8 ohms accross the switch posts (specs say between 3-7 ohms is OK). Also got continuity on the high amp connections when putting 12 vdc to the switch posts.

So the relay checks out. Will reinstall the relay and bypass the starter switch by jumping the switch posts from the battery to see if it will start thru the relay.

The headlight does go dim like there is a major amp draw when I try to start thru the switch. I've been told starters can develop a bad spot.... maybe the direct battery jump to starter was enough to get the starter kickin' where the relay won't.

Any more ideas welcome. Will try some things this evening.

John K
 

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Discussion Starter #6
Tested the clutch switch and it's good.

Cleaned the battery posts real well... a little corrosion on negative.

Still no change.

Can engage starter and turn engine over by jumping from battery posts direct to switch posts on relay.... of course it won't start then because the relay plug is removed to access the posts.

Still starts fine and runs by jumping direct from +battery post to starter post on relay. I rode to work today but had to stop for gas so had to remove the seat and jump again.

Time permitting, at lunch I'll see if there's any 12 volt signal delivered from the starter switch to the starter relay by putting a meter on the + and - leads coming out of the relay plug.

I could replace the battery even though it seems strong... couldn't hurt.
 

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If you have a voltmeter, try measuring the voltage across the relay while trying to start. Before you hit the switch it'll be something like 13.5-14 volts. When you hit the switch, it should be very near zero. You could also measure the voltage applied to the starter (it'll be what wever you're batt voltage is minus the drop across th relay). From your description it sounds like you have a resistive connection somewhere. Now the trick is to find where. If it's the relay, you see a significant (more thatn a volt or two) drop across the relay contacts. After that, it's a matter of follwoing the wire to the starter.

At least this'll give you something to do :roll:
 

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Discussion Starter #8
Finally found it.

After testing the ignition switch, kickstand relay, continuity from the clutch switch to the starter relay and just about everything else I could think of, I finally took the starter switch assembly apart and discovered the tiny lower stop tab on the switch button had broken off inside, preventing full depression of the switch. Had enought travel to disconnect the headlight but just short of contacting the contacts for the starter relay.

Just about have that electrical schematic in Clymers memorized by now.

Works fine with just the upper tab on the button - would replace the starter button but I think you need to buy the entire right assembly.

Thanks for the suggestions.

John K
 

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Good job finding the fault. Keep an eye on ebay for the switch. I see them quite often.
 

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Good work, glad you figured it out.
 

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Really, Dennis???
 
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