No power to ignition/dashboard

[WR450FGreg]

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My TRX has failed me for the first time!
It's a low km (18,000km), well maintained bike that normally starts easily and runs like a train.

I took it on a 6hr ride to Australia's Snowy Mountains on Friday. It was running fine, starting up easily each time we stopped for fuel/food/whatever.
Late in the afternoon I went to start it once again and it was dead. No power to the dash (maybe the gauges moved a tiny amount when the ignition was turned on, but it was hard to see them move) and it wouldn't crank over at all.

We pulled the seat off and checked all the usual fuses, connections etc. All are like new and seemed fine.
One thing we did do was short across two 8mm bolts, bypassing the fusebox (I think). The motor cranked over like normal, but wouldn't start.... so that eliminates battery trouble.

It cost me $400 to get it and me transported home!

Any suggestions as to what I should look for today? I have a multimeter but I'm somewhat "electronically challenged".

Thanks in advance.

[Tarwetijger]

I think you bypassed the starter relais?
I tought that could be your problem but than you should have some lights at the dash, of course....

[alextrx850]

If you could crank the motor by shorting through the starter relay proves that there is power there.
Having no power to the ancillary circuits would suggest the main frame earth has corrosion and won't ground, that with your suggestion that the fuses are Ok....the engine is earthed through its mounting back to the battery,so is different to the rest.
Check that your handle kill switch is on and might have a go at the side stand switch wires that run up inside the primary sprocket cover, a good chance of them being pinched and vibrating through to become earthed out...that won't explain why the clocks won't light up, but you might have more than one Gremlin in there.
Mostly the problem sounds electrical as if it was fuel ,the symptoms would be different.
The trx is a simple machine, so the fix most likely will be same., the bikes are getting long in the tooth these days, so folks will need to look at possible overhauls somewhat...wouldn't go up in a 15 year old Cessna that hasnt been serviced properly.
You would be looking for a frame earth ..and then go from there from your info.

[WR450FGreg]

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Thanks Alex!

I'm heading out to the shed to investigate right now.

Cheers,
Greg

[WR450FGreg]

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Ok, I checked the engine block earth, it seemed ok.
Sidestand switch was operating ok.
No pinched wires behind the sprocket cover.

I then tested the starter relay as per the instructions in the workshop manual.
It was supposed to read continuous (ie. 0 ohms) when powered up.
It read 1.5 ohms, but in view of the fact that I could hear it switching on and off as I connected/disconnected the power supply I figured that 1.5 ohms must be close enough.

I then checked the continuity of the wires coming out of the RHS switchblock, which seemed all ok.
After this I sprayed some silicon water dispersant spray in the switchblock, put it back on the bike and presto!....... Dash lights on and it starts/runs like normal!

Now, whether it was a dirty connection inside the switchblock, or that I have dislodged a wire that was earthing out I don't know.
Time will tell I guess.

Thanks again for your suggestions Alex!
At least they gave me some stuff to check.
I was at a loss to begin with.

I'm just about to take it for a test run now.

Greg

[alextrx850]

Sweet.
Food for thought, but a light spray with a penetrating oil does a lot of good in many ways....keeps wires earthing, rubber supple and easier to clean.

[WR450FGreg]

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All good after the test run.
I stopped and started it a few times. No problems at all.

[Gordo]

For me, in one word, INOX. Brilliant stuff as no eventual build-up of gummy dried out WD/penetrating spray.

It was originally recommended to me by a locksmith (due to the lack of "gumming" in lock mechanisms) for a Datto I had, long gone now but, still keep a can of the stuff handy & it's excellent.

Gordo-

[WR450FGreg]

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Thanks Gordo.

I've got a can of that in the shed too!
Didn't think to use it. Doh!