Starting issue

[Rex Winters]

All, sorry I have been absent for awhile. Long story. My 06 k9 wouldn't start the other day after I stopped for a few hours. Acted like battery was dead. I tried push starting and jump starting it. It ran once for a minute and died. Put a new battery in it and it would crank but backfire badly. Pulled the starter and checked all the wires to make sure I didn't have a grounded wire. Put it all back together, and it won't even try to crank (nothing) with a fully charged battery. Plus the headlight isn't coming in now. I replaced the ehc with the pdm a few years back and I have tripled checked my wires from battery to the rest of the bike. Plus I even tried a different pcb for the right side controls. Wtf??

 

[roadie1389]

That PDM is a pain. First I would check all the fuses. Do any of the other functions work (horn, signals, brakes...)

 

[Rex Winters]

Yep. Checked all the fuses. Horn, signals etc all work.

 

[Jersey Big Mike]

I'd turn it on and put it in neutral then use a piece of wire to connect +voltage to the starter solenoid - green wire I believe with spade lug -- you can jump it right to the large screw terminal on the starter.

Don't hold it there long. If it starts I'd start chasing thing from the had controls back to the PDM/HCI

Have you tried going to high beam for the light since you say its out.

 

[Rex Winters]

Tried high beam... Nothing there either. Tried a positive wire to starter and it goes "err" then stops. Like the battery is low.... Even though it isn't. With the dead battery, the backfiring, then no starter movement, and now no headlight I am leaning towards pdm. Am I way off base here?? My options are to troubleshoot more, or replace the pdm with either the original ehc, or change to a wp or whatever.... Damn this gets annoying

 

[Jersey Big Mike]

Tried high beam... Nothing there either. Tried a positive wire to starter and it goes "err" then stops. Like the battery is low.... Even though it isn't. With the dead battery, the backfiring, then no starter movement, and now no headlight I am leaning towards pdm. Am I way off base here?? My options are to troubleshoot more, or replace the pdm with either the original ehc, or change to a wp or whatever.... Damn this gets annoying

Ok, that only going err with the battery right to the starter worries me.
My next step would be disconnect all the other electrical connection to battery.
Make sure you have the ground connected and its good on both ends
Make sure the battery is connected to the starter and try the bypass starter relay again with wire.
If it just goes err again, load check the battery and or, plug the plugs (releases compression) and see if engine spins.
This eliminates the PDM at that point, so if it doesn't spin and the battery load tests properly you'll have a place to start.

My fear for you at this point is you may have more than one thing going on. LOAD check that battery somewhere - at room temp you should have around 500CA -- the 310 rating is CCA (cold) too many times batteries people swear are good turn out to be the issue (i've done it myself).

Can you swap back to an EHC after a PDM upgrade without any issues?

 

[Rex Winters]

Ok. That makes sense. Hadn't thought of bypassing the pdm entirely. I will check those things. I hadn't thought about battery because it is brand new, but I guess it is possible it is defective. I imagine I can put the ehc back in, but a pita.

 

[HMAN]

Pull ur headlight apart and look for a burnt plugin. Jm thoughts, but the WP I have in the Pit will not start if both hi n low beams are out. You be experiencing similar issues?

 

[Jersey Big Mike]

Ok. That makes sense. Hadn't thought of bypassing the pdm entirely. I will check those things. I hadn't thought about battery because it is brand new, but I guess it is possible it is defective. I imagine I can put the ehc back in, but a pita.

Process of elimination

 

[roadie1389]

I had a PDM and when my starter crapped out it created a surge and fried the PDM. The PDM is full of shitty electronics and a really poor protection circuit. I took it and thru it in a box and bought a RIP. It was just the last in a long line of poor choices of BDM. It is really hard to debug the PDM but you can get to the white connectors and probe with a voltmeter various inputs. I suspect that side of the circuit is crapped out (mine did the same thing, no headlight, no start, no tach). You have the schematic of it?

 

[Rex Winters]

I don't have the schematic... At least can't find it. Lol. Took out the starter again and found the relay connection was broke inside the starter. Resoldered it. Now the starter spins outside the bike on a battery. Now to reinstall and see what happens.... I still lean towards the pdm.... Checked fuses and they are all good. Time for more troubleshooting.

 

[Rex Winters]

Pull ur headlight apart and look for a burnt plugin. Jm thoughts, but the WP I have in the Pit will not start if both hi n low beams are out. You be experiencing similar issues?

Checked the bulb and it is good. I am only measuring 3 volts to the socket though. The plot thickens. Still suspect the pdm