[BAB]

I have checked the black and red wire at coil and there is a constant 12 volts. The green and yellow wire voltage fluctuates and drops below the 100 volt minimum and then will return to above 100 volts. When the voltage is correct it will try to start but dies when the voltage drops below 100. The CKP sensor has tested fine with a steady voltage around 5.4. I have cleaned the ground wires and electrical connections. I also bought a new PCM and coil but have the same problem. Any guidance would be appreciated.

 

[retro]

You can get a free copy of the service manual HERE to aid you in diagnosis.

You didn't say much about the history of your bike.... has any of it been replaced with non-oem parts?

Welcome to the forums!

 

[BAB]

Thanks for the welcome and the bike is all original. My son was riding one day and said it started to run rough and would quit. The bike would start and go a few feet and just stop like you had turned it off. I found the service manuals and followed the trouble shooting guide under the ignition system. When the bike would not run it had no spark and there would be no voltage at the green and yellow wire on the ignition coil. If you kept attempting to crank it voltage would eventually return to the green and yellow wire. There would always be the correct voltage at the PCM connector for the CKP sensor. The troubleshooting guide showed if there was no voltage it was a faulty PCM. Bought a new PCM and it fired right up and I thought the problem was solved but apparently not. Drove it about 200 yards and it died. I have only had a limited amount of time to trouble shoot but here is what I have done:

1) Replaced PCM
2)Cleaned IACV
3)Cleaned electrical connections and grounds
4)Drained fuel system and cleaned fuel filter

When you turn the ignition on you can here the fuel pump come on and the IACV valve operating. I have been looking at the service manual while typing this and noticed a faulty engine stop switch could cause no voltage. Not sure how I overlooked that, but maybe I have been looking in the wrong places for the problem.

 

[retro]

Ya, the kill switch (or its harness plug) is more likely to be the problem. Operate it back and forth a few times and if symptoms improve a bit you're onto it. Let us know how it goes if ya can.

 

[BAB]

Its alive!! I flipped the kill switch back and forth several times and it crank and has run perfect. I have looked at the trouble shooting guide in the manual several times and can not believe I kept over looking the kill switch. Is there a way to clean the switch? I did not see anything in the service manual but I may have over looked it also. Thanks for the help.

 

[retro]

Yeah, you should maintain the switches. All of the connector plugs on the wiring harnesses fall into this same category of maintenance too. If they get wet and stay wet they can corrode & rot pretty quickly. As for how you want to handle that its up to you... & your comfort level working with those small switches. Some folks just spray lubes into them and hope... I take them apart and use polar-bonding lubes on them. Its your call... Use a good quality di-electric grease on all of the harness connectors to weatherproof them.