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post #1 of 62 (permalink) Old 03-27-2019, 02:11 PM Thread Starter
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Wont start

Ok, 1st some history. Last spring I ran the control wire at the bars internal in the bars, 12" mini apes. Mid summer I replaced the battery, tested bad. Moved from Ga. to Indiana last fall and trailered bike here, because it would not start. I could jump the selonoid to start it. Replaced selonoid before winter and it started several times just fine. Was leaving work one night and noticed the tail lights, and brake lights were not working. They still arent, once I push the brake pedal or pull the handle, fuse blows. Now its not starting again without jumping the selonoid. Battery was just taken off the charger right before I started checking it today. Took the start button apart and cleaned it thinking this could be the problem, no change. Its an 05 800 I bought new in feb 06, and all of the 114k plus miles on it are mine. Runs fine once started.

2005 800 classic
2012 Voyager ABS
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post #2 of 62 (permalink) Old 03-28-2019, 05:31 PM
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Do you still need help with this?
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post #3 of 62 (permalink) Old 03-29-2019, 12:57 AM Thread Starter
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Was kinda hoping you might chime in here. Yes I do. To answer your next question I'm guessing, I do have a meter, its a Morris #57240 clamp meter. I work afternoons until early morning, so may take a bit to reply. Am off this weekend, so want to try to figure it out then if possible, but no real rush. Oh, this meter is much smarter than I am I believe.

2005 800 classic
2012 Voyager ABS
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post #4 of 62 (permalink) Old 03-29-2019, 12:12 PM
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1. To verify, bike will not run or will not crank?
2. Did bike run after bars install?
3. Which fuse blows?
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post #5 of 62 (permalink) Old 03-29-2019, 02:19 PM Thread Starter
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Rode the bike last summer after wiring bars internally. About the end of July replaced the battery after it went bad, this is my 3rd battery since buying bike new in feb of 06.Hit starter button and get no response at all, dash light dont dim any any starter does not try to engage. The fuse that blows is for the tail light and brake lights, blows as soon as the brake switch is activated. If I jump the 2 large post on the selonoid, it'll start right up and runs fine.

2005 800 classic
2012 Voyager ABS
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post #6 of 62 (permalink) Old 03-30-2019, 11:53 AM
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Ok, we will tackle the no crank first, and maybe will spot the fuse issue while doing this:

1. On junction box, locate black/red wire.
2. Push red meter lead down beside wire to contact pin.
3. Black meter lead to battery ground.
4. Key on, push start button and take voltage reading.

Post back with reading and any questions you may have.
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post #7 of 62 (permalink) Old 03-31-2019, 12:12 PM Thread Starter
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11.74 at connector, 12.50 at battery post. The 11.74 was at the plug on fuse box, this where you needed reading?

2005 800 classic
2012 Voyager ABS
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post #8 of 62 (permalink) Old 04-01-2019, 10:06 AM
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OK:

1. On starter solenoid, push red meter lead down beside yellow/red wire to contact pin.
2. Key on, take reading. Push and hold start button and take another reading.

Post back with 2 readings.
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post #9 of 62 (permalink) Old 04-01-2019, 10:55 AM Thread Starter
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Key on got 1.24 but slowly dropped until I took lead off. Key on, pushing start button 11.72, steady reading.

2005 800 classic
2012 Voyager ABS
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post #10 of 62 (permalink) Old 04-01-2019, 12:32 PM
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Put finger on start solenoid, key on, push start button and can you hear/feel it click?
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