Same starter issue, electrical

[gumby302ho]

  Okay I replaced starter relay and same issue, no start from the push button. Manual says " Disconnect the starter relay blue\wht connector and connect a jumper wire from the connector to ground, operate the starter!!! this might be my issue. When I jump the relay to ground my starter fires(without pushing start button) so I followed next step which said the relay was bad. Replaced the relay, same issue, no start from push button. I believe I might have a bad start button/headlight issue all tied in. When I turn the key on sometimes the headlight wont come on, if I push the starter button the headlight will come on. Another fact of my FrankenJ is that you could always cycle the starter without the key on.      I have always been haunted by bs electrical, most times I can get through but I cant stand one pesky little god knows where wire and having to trace and rip and poke, I am just not good at it. Any thoughts.
    Don

[roverfj1200]

If you ground the relay and the starter operates the relay is fine. The problem will most likely be a side stand switch clutch switch neutral switch and so on.

[Mark Olson]

You have more problems than you think.  the push button starter sw. should not operate the starter without the ign turned on.

Unfortunately you are going to have to use a meter to trace your system for the problem .. off hand it sounds like a bad ignition switch with a bad push button starter switch as well. 

Without tracing the wires out you will just be throwing parts at the problem with your fingers crossed.  It sounds like your wiring is grounded/shorted somewhere . bust out the manual and follow the schematic and you will find something messed up along the way. A common source of problems is the right leg side of the fj wiring connector near the faring towards the front of the bike. Sometimes a loose connector will cause mayhem.

[gumby302ho]

If you ground the relay and the starter operates the relay is fine. The problem will most likely be a side stand switch clutch switch neutral switch and so on.

Side stand switch already by passed from PO. The bike started up great for a good spring warm up( it has always rolled over from push button but no ignition again from PO, the guy did some real good work though so I am not throwing him under the bus. Do FJ headlights switch off when starter rotates from the push button? Starter in brand new, this baby has always rolled over, now when I turn ignition on the push button if pushed and frigged with the headlight will come on. Im thinking its the push button, any fellow FJ'rs have ever had a bad start button?

[Mark Olson]

yes,, on the start button.

yes it affects the headlight. head light turns off when start button is pushed .

The start button is serviceable , take it apart and clean contacts .. this may solve your dilemma.

Your FJ sounds like it has some custom wiring from the PO. 

[Arnie]

Yes, on the start button.
I cleaned and then soldered some extra material to the contacts which worked for a couple of years.
Then, the button itself (the bit you push) jumped out of the housing and made its' escape.

A kind and generous member of this list sent me his "old" complete switchblock to replace mine.
I'm very grateful.   

[Swedenbill]

Don, I just had the starter issue and it turned out to be the starter switch although I did replace several connectors in the wiring. The problem with the starter switch is bad design. It works by sliding the contacts together. Better is if you had a vertical connection. However, most of these vertical push switches are round. I have an extra start switch housing that I will try to modify to fit a universal round/push switch. You might try spraying WD40 into the start switch as I did. It seemed to work as grit/dirt came out. It is likely that the grit/dirt came between the sliding plates, hence no contact.

Swedenbill

[gumby302ho]

 So my hunch was good but a couple Fj brothers helped guide me. So it was the starter button after all, what a strange setup, so I guess our headlight circuit runs between two tiny tiny nipples that make contact on a flat surface inside the switch, yikes, I pulled it apart and cleaned and lubed but the spring will be the end of this guy, its working now but for how long I don't know. Can new controls be bought, any other yamaha models that closely match? Or will I have to rebuild this old switch like Steve Austin! An FJ Barely Alive, we have the capability!! Thanks all for the input