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Starter relay issues, '80 GS850G

  • Thread starter Thread starter williampkerr
  • Start date Start date
W

williampkerr

Guest
I have 1980 GS850G that I'm trying to bring back to life. I am very new to wrenching on motorcycles. I'm learning as I go. A couple weeks ago I actually got combustion and it ran for about a minute. Since then the starter button has not been working or maybe it's the starter relay that is broken. When pressing the starter button the starter relay won't engage, thus no power to starter motor. I can jumper the starter relay and get power to starter motor though. I have continuity tested pretty much everything. Here is what I have tested:

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1)When ignition switch is in "ON" position the ignition switch is showing continuity between red and orange wire. Also showing continuity between gray and brown, but this doesn't concern me at this point in time because those the gray and brown are for various lights.

2)With the ignition switch in the "ON" position both the red and orange wires are reading 12.2v

3)With the start button depressed (pressed in) I'm showing continuity between the yellow/green and orange/white which proves the start button is making good contact.

4)From the emergency stop switch in the "OFF" position I tested continuity good from orange/white (the orange/white that doesn't jump to the starter button) all the way to the fuse panel AND back up to the solid orange at ignition switch.

5)From the emergency stop switch in the "OFF" position I tested continuity good from orange/white (the orange/white that does jump to the starter button) to the ignition coils and to the connector at the ignitor unit (CDI box)

6)From the emergency stop switch in the "RUN" position I'm showing continuity between the two orange/white wires and when the emergency stop switch is in the "OFF" position I'm not showing continuity between the orange/white wires (which is as it should be of course).

7)Tested continuity good on yellow/green wire at the starter button all the way to the starter relay.
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The only thing I can think that would be the problem is that the starter relay is broken and not engaging the power jumper mechanism inside the relay. Is there any further testing anybody suggest I do? Or should I just by a starter relay online. They aren't very expensive so I'm totally open to buying one if you all suggest I do so. Thanks for taking the time to read this post and any suggestion or advice in general beyond this immediate issue would be greatly appreciated as well.
 
williampkerr said:
The only thing I can think that would be the problem is that the starter relay is broken and not engaging the power jumper mechanism inside the relay. Is there any further testing anybody suggest I do? Or should I just by a starter relay online. They aren't very expensive so I'm totally open to buying one if you all suggest I do so. Thanks for taking the time to read this post and any suggestion or advice in general beyond this immediate issue would be greatly appreciated as well.
Click to expand...

Common problem is to lose the ground on the solenoid. It could also be broken but before replacing it make sure the solenoid is grounded. You could also ohm out the solenoid coil to check it. That is about the only thing that could be bad unless it has melted contacts. The think is actually fairly easy to disassemble as well.
 
posplayr said:
Common problem is to lose the ground on the solenoid. It could also be broken but before replacing it make sure the solenoid is grounded. You could also ohm out the solenoid coil to check it. That is about the only thing that could be bad unless it has melted contacts. The think is actually fairly easy to disassemble as well.
Click to expand...

Thanks for the quick replay. If I'm not mistaken the relay is already grounded because it connects to the starter which in and of itself is grounded, correct? Regardless, I decided to remove the relay and inspect it by disassembling it. Upon doing so I broke it, lol. One of the coil wires broke. So i continued to inspect and found a small bit of rust at one the coil terminals. I think ultimately I would have had to replace the relay even if I hadn't broke it, wouldn't you agree?
 
williampkerr said:
If I'm not mistaken the relay is already grounded because it connects to the starter which in and of itself is grounded, correct?
Click to expand...

posplayr said:
You are mistaken.
Click to expand...
The solenoid (relay) does not "ground to the starter". There is a switched HOT wire that goes from the solenoid to the starter, but that's all.

The solenoid is grounded to whatever it is mounted to, usually the battery box, which is rubber-mounted and needs its own ground wire.

.
 
I've also had this issue once. And like others have said, it needs it's own ground wire. What I did was to make a ground wire with a connector on each end. Then I put one connector under one of the bolts that mounts the solenoid to the bike and the other connector to a different ground point. Fixed it right up!
 
Try pulling in the clutch while starting.
Make sure the kill switch is on.
 
For future reference, to check the solenoid in isolation you can disconnect the green/yellow wire from the wiring harness and touch it to the positive side of the battery. You may need a jumper wire to do this.
 
Super said:
I've also had this issue once. And like others have said, it needs it's own ground wire. What I did was to make a ground wire with a connector on each end. Then I put one connector under one of the bolts that mounts the solenoid to the bike and the other connector to a different ground point. Fixed it right up!
Click to expand...

I did what you suggested (as it wasn't previously grounded per the earlier threads). I made a ground wire with two connectors that starts between the solenoid and battery box and ends between where the battery box meets the frame. I test continuity from the solenoid to the frame successfully but I'm still not getting any action from the starter button. Also, I have a brand new solenoid. I tested it by jumping with a screw driver between the two solenoid posts and the starter motor engaged. Once again I'm at a loss.
 
eil said:
For future reference, to check the solenoid in isolation you can disconnect the green/yellow wire from the wiring harness and touch it to the positive side of the battery. You may need a jumper wire to do this.
Click to expand...

If I'm understanding you correctly you are suggesting to jump from the green/yellow wire at the solenoid to the positive on the battery? I did that and nothing happened. I have a brand new solenoid too. The only way I know to test it is by jumping between the two solenoid posts with a screwdriver. I know that this is an unsafe tactic but it worked to get the starter motor engaged. Once again I'm at a loss.
 
chef1366 said:
Try pulling in the clutch while starting.
Make sure the kill switch is on.
Click to expand...

I have made sure the kill switch is on and I have also verified that the bike is in neutral. I engaged the clutch as you suggested and still no action from the starter button. I don't have the gear position indicator connected so engaging the clutch shouldn't make a difference. Am I correct in this assumption?
 
AND the solenoid body (metal shell) must be grounded to the battery as well. Hook a jumper or a wire between the batteries negative post and the solenoids metal shell then retry powering the green/yellow.
 
Greetings and Salutations!!

Greetings and Salutations!!

Hi,

You'll find some troubleshooting tips in the links below. :dancing:

If you are here you probably have a 30 year old motorcycle that needs about 20 years worth of maintenance. In the links below you'll find maintenance lists, documentation, wiring diagrams, "how to" guides, vendor links, tips, tricks, and a whole lot of GS goodness. This is your "mega-welcome". Let's get started. :)

Let me dump a TON of information on you and share some GS lovin'. :D

I just stopped by to welcome you to the forum in my own, special way.
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If there's anything you'd like to know about the Suzuki GS model bikes, and most others actually, you've come to the right place. There's a lot of knowledge and experience here in the community. Come on in and let me say "HOoooowwwDY!"....
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Here is your very own magical, mystical, mythical, mind-expanding "mega-welcome". Please take notice of the "Top 10 Common Issues", "Top 15 Tips For GS Happiness", the Carb Cleanup Series, and the Stator Papers. All of these tasks must be addressed in order to have a safe, reliable machine. This is what NOT to do: Top 10 Newbie Mistakes. Now let me roll out the welcome mat for you...

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Please Click Here For Your Mega-Welcome, chock full of tips, suggestions, links to vendors, and other information. Then feel free to visit my little BikeCliff website where I've been collecting the wisdom of this generous community. Don't forget, we like pictures! Not you, your bike! :D

More links to helpful threads in the forum:
Help! Your Bike Won't Start
DON'T DO THESE THINGS
Help! Your Bike Won't Run Well
Oh God! Pods!


Thanks for joining us. Keep us informed.

Thank you for your indulgence,

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rustybronco said:
AND the solenoid body (metal shell) must be grounded to the battery as well. Hook a jumper or a wire between the batteries negative post and the solenoids metal shell then retry powering the green/yellow.
Click to expand...

SUCCESS! Thank you so much! So the solenoid needs grounding to the frame and to the battery? I have lots to learn apparently!
 
The solenoid needs to be connected (grounded) to the batteries negative post. How it gets connected to it, either through the frame, or a wire, doesn't matter. The usual way is solenoid> electrics panel> wire to frame (or batt neg). Batt neg is connected to engine, wiring harness and frame.

Do you now understand the path?
 
rustybronco said:
The solenoid needs to be connected (grounded) to the batteries negative post. How it gets connected to it, either through the frame, or a wire, doesn't matter. The usual way is solenoid> electrics panel> wire to frame (or batt neg). Batt neg is connected to engine, wiring harness and frame.

Do you now understand the path?
Click to expand...

Gotcha, I understand now. Thank you.
 
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