:( Electrical Woes Again. 2005 620, Whhhyyyy!?!!

[evoasis]

I'm hoping it's just the battery, which is less than a few months old.  Hadn't started it in almost a week.  Won't turn over, just makes that click click click noise @ the relays.  There was some gunk under the negative terminal of the battery, too :/

https://www.flickr.com/photos/31253172@N08/4753042573/#secretea5b236b80-w500-h375

[evoasis]

So yeah, the only thing that happens is that one of the relays clicks continuously, starter will not engage, and bump start doesn't do squat but turn the engine over.  The pump sounds like it continuously is priming thou~!

I've read on forums of people w/ this similar issue due to a faulty ecu ground, but I traced the grounds and applied fresh coats of dielectric grease to no avail.

Any idears other than an engine swap?

[Asmig]

Inspect and clean the main fuse for the ECU. I had the same issue and it was due to corrosion at the fuse terminals. My bike had come from a wet climate (Florida) and virtually every connection needed thoroughly cleaned and dielectric grease applied. I also had to empty nearly a cup of water from out of the gauges as well. 

[Bones]

so have you cleaned and checked your connections at the solenoid, the main ground to the chassis and connections at the starter?
you should also check voltage on the battery. sounds like this may (hopefully) be just a low battery/bad connection issue.



..ohhh. it looks like it starts doing that as soon as you turn on the ignition, even without you pressing the starter button.   

hmmmmm... check solenoid connections and unplug the starter switch from the harness to see if it stops.

[Howie]

1.  Charge and load test battery
2.  Clean terminals and reconnect.
3.  Check ground on engine by breather.
4.  Check charging system output.

Then start looking at more esoteric problems.

[suzyj]

Aaargh.  This is such a recurring theme.  We need a sticky with a pointer to the elecsys troubleshooting flowchart.

Given that you battery voltage is 12 odd volts, it looks like the starter solenoid isn't engaging, or else there's a connection issue between the battery and the starter.  Check the voltages at various points between the battery and starter, and also check the voltage on the starter solenoid coil.

[ducpainter]

1.  Charge and load test battery
2.  Clean terminals and reconnect.
3.  Check ground on engine by breather.
4.  Check charging system output.

Then start looking at more esoteric problems.

I don't believe the injected bikes don't have the ground by the battery.

[Speeddog]

Do Howie's list.

Spontaneous behavior like that isn't generally a good sign.

Try swapping the small relays mounted to the left front of the battery box.

[evoasis]

Yeah I trickle charged, went over alllll the connections (listed by Howie/etc) with a brush / grease to no avail.. Left the starter unplugged and it had the same ticking noise when I turned the key.  Keep in mind, I'm not engaging the starter when the ticking noise happens at the relays, and I've swapped em with one another/ new(er) relays to no avail.

Also, I trickle charged it over night and today it is at 13.1v.  The battery is rather new (Interstate) which is still warrantied so I may try exchanging it today and see if that solves my problem.

I'm hoping it's the battery, but it may be that solenoid coming from the Pos terminal to the starter.  I'll get into it again in a minute.

I appreciate all the tips guyssss!

[Privateer]

you better have a beer for me to drink while you're taking the battery out of my bike to test.

[evoasis]

Oh shit man I didn't read your post til now! gah damnit man you shoulda said where's my beeer!

hahaha

Anyways an update for those who care to hear, Privateer and I tried a battery / Relay swap to no avail.  However, I took off the headlight and unplugged the two harnesses up front there and the bike is now making different funny noises.
-
This leads me to believe that it's prob ecu related.
-
Also, the fuel pump continuously primes the engine.  I'm going to go through the harnesses tomorrow for further inspection/ greasing   Thanks Privateer you're truly motivation to the souuulll!

[Privateer]

Oh shit man I didn't read your post til now! gah damnit man you shoulda said where's my beeer!

hahaha

Anyways an update for those who care to hear, Privateer and I tried a battery / Relay swap to no avail.  However, I took off the headlight and unplugged the two harnesses up front there and the bike is now making different funny noises.
-
This leads me to believe that it's prob ecu related.
-
Also, the fuel pump continuously primes the engine.  I'm going to go through the harnesses tomorrow for further inspection/ greasing   Thanks Privateer you're truly motivation to the souuulll!

yeah those two relays went from a click click click to a buzzzzzzzzzzzzzzz to nothing.

At one point while unplugging and plugging things in different combinations, turning the key to on and not thumbing the starter caused the engine to start turning over, but wouldn't fire.

I'm not mechanic, but I blame ghosts.

Let me know if you need to come over another time to drink your beer and heckle you while you flail about.

[beatcat]

This probably won't be that helpful but i bought a new ECU and gauge on ebay and hooked them up and my bike made the exact same noise. When i plugged in the ecu--it wasn't actually mounted on the bike--i just hot swapped the plugs. As soon as i heard that noise i got scared and  restored everything and it was all good. A stab in the dark would lead to something ground related and definitely ECU related. sorry i can't help anymore---i do have a spare ECU you could try out. (Yes it's the one that made my bike make that noise ;-)

[evoasis]

But ECU's are locked to the gauges, mine is an aftermarket ecu (doh) and the bike is being way too goofy right now.

[evoasis]

Update of what happens..
My bike