Almost there..but now nothing. help!

well i was finally getting somewhere on my bike. I finished the wiring connections and checked them. lights all came on and the oil light was on so i could start it, but i unplugged the wire and it would turn over fine. well i got done with the pain of hidding all the wires and i tested it and same thing, neutral light etc. came on and turned over. so i put the tank back on and got to filling the bike with oil on the frame stand. filled it to just below the max line and i went to start the bike and the oil light still was on and now the neutral light was off. wtf?, so i unplug the oil sensor wire but it didnt turn over like before it just flashed the oil light every time i pushed the starter.

So now i am stumped as to why the neutral light is off and why its not recognizing my oil change which is full on the nuts. Anyone have any ideas for what i should check? i want to start this thing so bad, but i got all the way to filling it with gas and it does this.

any help would be great! thanks

 

If it's in gear it won't turn over without pulling in the clutch and the sidestand has to be up, unless your sidestand switch has been bypassed. Neutral light might be off because you bumped it into gear; or you got the wires from the oil level sensor and the neutral switch mixed up. These bikes have a "safety relay" system that prevents you from starting the bike in gear or with the sidestand down. You can unplug that relay for troubleshooting purposes but do not leave it unplugged as the bike could then be started in gear, not a good outcome to that. Do you have a service manual yet? You really need one for these bikes, a factory one if you can swing it.

 

its in neutral for sure. i just dont know why now its not working. but the oil light is the only think bothering me. it had no oil so i did a full fill and filter. i put about 2.5Qts in it but its still showing the light. so should i just leave the key on and fill till the light goes off?

i DL'd a stock manual to my comp and it should help a little. just asking if there were any little things im missing. thanks for the help though!

 

No, don't overfill the crankcase. You should be just above the "top" mark in the sight glass, with just a "bubble" showing. The oil level sending unit may be FUBAR. I'm not anywhere I can touch a manual right now, hopefully someone can chime in with how to check it.

 

Assuming it is the same as the 650

It is a float switch that has a single wire. When Oil level is low it grounds the wire turning on the light and engaging safety cut off circuit also.

So you can disconnect the wire coming from the sensor and check continuity to ground. If it shows continuity it is shorted or stuck.

 

i never thought of it sticking. the PO had the motor empty of oil for a while so maybe it got gumed up and stuck down. would i have to rip into the motor to fix it or is there a simplier way?

its just weird that before i had oil in it i could turn it over if i unplugged the sensor. but now even unplugged it turns the oil light on when i press the starter in.

 

haha well i knew it was somthning dumb..and it sure was. somehow i had the oil wire in the neutral spot and the neutral in the oil spot. IDIOT! lol but i dont remember switching them

 

well i got it all togther but i get no spark. i tested the coil connectors with the bike on and it shows no power getting to them. is this most likely a bad TCI unit? or should i take the case cover off and look at the pickups?

i want to start it bad before winter. but its just making me want to take it somewhere and see if someone else can do it for me.

 

anyone? i have a guy with 81 550 parts bike near by so i'm just wondering if i should crap the unit off that bike or the coil pickups etc.

i havnt taken my case off yet to check the coil pickups, but its been too damn cold to get out there, or make myself get out there. It has no spark in all 4 and all my wiring is correct, and the safety relay is clickn

 

IGN fuse take a close look at your fusebox especially if its the stock one.

 

I agree. 12V to the coils is switched on by the igntion switch and passed through the ignition fuse. The TCI unit grounds and un-grounds the coils, but they should be getting 12V all the time.

Also make sure that the engine stop swtich is not set to STOP.

 

if the fuse was out, or bad connection, wouldnt it not turn over? cause it turns over and all the fuses are good. but im going to replace he fuse box this weekend for an aftermarket one. so i'll see if that changes anything.

 

This might sound easy or stupid but on mine the Kill switch has no writing left and there is no way to tell if it's on or off. I was checking every fuse and connector are doing some wiring. All I had to do was the kill switch. KISS (keep it simple stupid)