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Discussion Starter #1
Finally got the hard bags installed and I wanted to drive the Bike to work.
A mile from my house, in first gear turning left at a light, the bike just died.

This is the second time. Both times it wont start until the key is turned off then on, then starts on first crank.

Same tank of gas as last time. Last time it was almost full, this time almost empty. Both times outside temp was high 80+

It feels like the kill switch was tripped. Not that I think that is what happened, but rather describing the feeling. Just dead.

Bike is a 2005 VN1600a with 10k miles, and appears to be bone stock, except for the bad ass road king leather hard bags I just put on it ;-)

Where to look first? Kickstand switch? Could that be it?

 

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1. How many miles on the bike?
2. How long have you owned?
3. When it dies, do running lights go out?
 

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Discussion Starter #3
1. How many miles on the bike?
2. How long have you owned?
3. When it dies, do running lights go out?
Well hello, I read a thread you posted in a lot about a similar problem.

Bike has 10k miles
I have owned it a very short time, 2 months?
I don't know. Both times it was very sunny.


I posted about the first time here http://www.vulcanforums.com/forums/15-vulcan-1600/253522-bike-died-me.html

I don't think its a tank pressure issue anymore. After reading the post I spoke about, I think maybe a short. Battery is suspect too due to not knowing anything about its history.
 

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I do not think it is a battery problem, yet.

1. When you turn key off and on for a restart, is the sidestand down and in neutral?
 

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Discussion Starter #5
No, I was in traffic so I pulled clutch, pushed start button. Cranked longer than it should. I then cycled ignition and again pushed starter and cranked right away, like always.
 

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OK, try this:

1. Start engine.
2. Grab ignition key and rock back and forth slightly towards off and park positions.
3. Tap on body of key switch with the butt end of a screwdriver.
4. Tap on end of key with same screwdriver.

In above cases, see if engine sputters or?
 

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Discussion Starter #8
OK, try this:

1. Start engine.
2. Grab ignition key and rock back and forth slightly towards off and park positions.
3. Tap on body of key switch with the butt end of a screwdriver.
4. Tap on end of key with same screwdriver.

In above cases, see if engine sputters or?
1 check. Engine died on me twice within first 30 seconds. Never done that. Once, but never twice. Strange, but I think insignificant.

2 engine (and ignition) dies very easily when key is rocked toward off. But when it does, the speed cycles and bike starts first push of the starter. Imediately.

3 so, I tap. And I shit you not, I think I see the tiniest puff of smoke! Coming up from the switch. Durring the entire tapping test bike ran fine. And I smacked it pretty good. Mostly trying to replicate what I saw. I removed bezel and tapped again, hard. Every 4 or 5th tap I see a tiny puff of what I can only discribe as smoke. I removed the two bolts holding the switch and held it in the palm of my hand and smacked it like I was cracking a nut. Bike never stalled out sputtered. I disconnected switch, engine quit, as I suppose it should. Plugged switch back in, installed bolts, bezel. Tapped switch with butt of screwdriver, puff.
4 tapping key did nothing.
 

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Discussion Starter #9
Houston, we have a problem.

Took bike for a ride, well I tried.

Bike idles fine, low RPMs fine, tried to accelerate out of neighborhood, bike bogs and FI light lights up. I let off the throttle. Light goes off, bike keeps running. I rev engine, FI light lights up, exhaust sputters, RMPs fall, light out, bike runs.

I turned around and rode home (low RPMs)

At end of driveway I reved engine in neutral. No tach but I would guess 1500-2000 RPMs = FI Light and bog. If i advance RPMS, The engine dies and will not start until I cycle ignition where I hear the fuel pump wind up and down like normal.
 

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Discussion Starter #10
Ok after a bit of searching I see where you advised tapping on the DFI relay.

I pulled the side cover and lifted the relay off of its rubber mount and pulled it down (coolant tank)

Turned on ignition and felt relay click.

Started bike and tapped. Nothing. Bike just idled nicely.

Revved engine RPMs and bike sputtered and FI light came on like above, but will not die if I let off of the gas.

I removed the rubber sleeve the relay is in and again tapped at idle. Sides and top. No change to the engine. I turned off engine, removed relay from the plug, contacts where fine, clean.

Turned key on and felt it click. Started bike, I then held relay to see if I could feel it click when RPMs increased, revved engine and it ran fine. No sputters up into high RPMs

I reassemble bike and rode it down the street. Did fine for a minute, then FI light lit up and then it died.

I tried to restart but it wouldnt until I cycled key.

Started right up and then I rode it up and down the street upwards of 50 mph and it didnt display anything wrong.

Parked it in the garage and shook my head.
 

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1. Be very careful in jumping around in your troubleshooting for fear of introducing another problem, and then the REAL tail chasing begins.
2. Any key switch that smokes when tapped should be replaced whether it is the problem, or not.
 

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Discussion Starter #12
1. Be very careful in jumping around in your troubleshooting for fear of introducing another problem, and then the REAL tail chasing begins.
2. Any key switch that smokes when tapped should be replaced whether it is the problem, or not.
I was afraid you would say both of those things.
 

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Discussion Starter #13
1. Be very careful in jumping around in your troubleshooting for fear of introducing another problem, and then the REAL tail chasing begins.
2. Any key switch that smokes when tapped should be replaced whether it is the problem, or not.
Other than replace the ignition switch, any other suggestions?

I am currently looking for a new switch to the tune of $150.

I promise not to jump ahead again :sidefrown:
 

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Discussion Starter #15
Nothing at this time as the switch is suspect.
Well i am both delighted and embarrassed to say i fix the issue.

I ordered a new switch and while waiting decided to inspect all electrical connections.

Negative battery cable was loose as a goose. Positive was not much better.

Tightened up both, runs like a scalded dog.

Guess you start with the easy stuff first for a reason.
 

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Usually, loose battery cables will show up when starting the engine.
Still, any switch that smokes is suspect.
 
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