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Starter Short Problem?

Discussion in 'The Garage' started by Davidz, Nov 1, 2017.

  1. Davidz

    Davidz XS650 Member

    So there's a short coming from somewhere that keeps blowing fuses every time you press the start button. I isolated the short down to the starter motor itself, but when I bought a used starter from eBay(tested and working) the same problem happens. Could there be a short beyond the starter in the motor, or where do I look? Thanks!
     
  2. gggGary

    gggGary Stop that! XS650.com Supporter Top Contributor

    Well even a dead shorted starter motor won't blow any fuses on a stock wiring harness so that wasn't it A shorted winding in the starter solenoid might blow a fuse. What year is your bike stock wiring or not? Welcome to the forum!
     
  3. Davidz

    Davidz XS650 Member

    Wiring is definitely not stock, but it has good continuity. Solenoid is good too. When I disconnect the cable going to the starter it doesn't blow fuses, only when it's connected does it blow fuses. Originally it takes a 20amp fuse, but I put a 30amp in and still blows it. Also, when I disconnect the cable on the starter and I hook up a test light to the terminal and then the positive side of the battery, it lights up as if it's grounded out inside?
     
  4. gggGary

    gggGary Stop that! XS650.com Supporter Top Contributor

    That would be normal the starter is a huge draw, and will pass plenty of current through the heavy windings to light a light bulb.
    A picture or three of the wiring would help. Is there a heavy cable with no fuse from the battery to one big solenoid terminal? That is how it needs to be set up. The starter circuit itself is never fused only the hot that runs the solenoid coil activating coil is on a fused circuit.
     
    Last edited: Nov 1, 2017
  5. retiredgentleman

    retiredgentleman XS650 Guru Top Contributor

    I agree with Gary. The problem is likely a defective starter relay (aka solenoid).
     
  6. gggGary

    gggGary Stop that! XS650.com Supporter Top Contributor

    This shows it pretty plain

    [​IMG]
    Note the heavy red wire from battery to starter with no fuses, the red white wire comes from +12 after the fuse and ignition switch, the blue white wire is grounded by the starter button to activate the solenoid.
     
  7. Davidz

    Davidz XS650 Member

    There is a fuse inline from the heavy red cable going to the solenoid on the wiring in my bike. Also the solenoid clicks just fine, could it still be bad?
     
  8. gggGary

    gggGary Stop that! XS650.com Supporter Top Contributor

    See diagram above, that wire is never fused. get rid of that, you should be fine.
     
  9. Davidz

    Davidz XS650 Member

    I'll try it out. Thanks a lot for the help!
     
    gggGary likes this.
  10. gggGary

    gggGary Stop that! XS650.com Supporter Top Contributor

    A rough estimate; the starter draws about 120 AMPS that's why you can't run them for very long, something will melt.
     
  11. Davidz

    Davidz XS650 Member

    That was the fix, thanks again for the help!
     
    gggGary likes this.
  12. retiredgentleman

    retiredgentleman XS650 Guru Top Contributor

    I can't believe what I just read! The heavy cable going to the solenoid had a fuse:yikes:.
    I guess the PO was a little short on electrical knowledge.
     
    gggGary likes this.
  13. Davidz

    Davidz XS650 Member

    The wiring on the bike is hacked up beyond belief. Going to rewire from scratch later on.
     
    gggGary likes this.

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