Forum

[tsflyer]

Hello Mates. Today I developed a total fail on my electrics on a '99 500 Bullet kickstart. This is a 12v system with Boyer box. Previously, it would happen intermittently until today's total fail. When I turn the key to the "on" position, I get nothing at all, no lights, no power to the Reg/Rect. Replaced battery with new. Using a test light, I get power from the battery, thru the main fuse and up to the ignition switch. On the back of the switch, there are 4 wires connected. Red, Blue and 2 Brown. With key in the "off" position, I have power to the Red connection only. In the "ON" position, I get power to the Blue wire and still the red....sounds right. SHOULD I BE GETTING POWER TO THE BROWN WIRES?? I do not have a schematic, but thinking this is where the fail is, in the ignition switch? Can anyone suggest a possible troubleshooting test to verify ignition switch is working properly? Is it unheard of for the switch to go bad or is this a common problem?? I've ruled out bad Boyer Box, Alternator and Reg/Rectifier since I get nothing at the switch...am I correct?? I do have a multimeter and would welcome any other tips for trouble shooting. I've traced every wire from the harness and behind the headlamp, and no bad connections or worn wires. Thanks in advance! Tim

[tsflyer]

OK, perhaps I posted too hastily? After a closer look at the ignition switch connection block, it appeared the Blue wire was pushing out of the rear of the block, ever so slightly. Disconnected, repositioned and connected, assuring complete contact. (strapped together with nylon tie now) Now, all is good.??? If I would used test light on the other-half of the block at the blue wire, I would be assured this was the problem. (I had power at the blue wire solder connection on the back of the ignition switch, which means I had power "to" the block - when key was ON) BUT, since I didn't check the wire at the back end of the block (after connection)....I can't be assured this was it?? I'll just have to ride it out and see! Tim

[Alan R]

Hi guys-----------now that's the sort of tech. enquiry posting that I like to see !!----- The Problem.......The Diagnosis........The Result..... all done by the owner..Nice one TSFLYER, welcome aboard..I think you were right to suspect the ign.switch though as they have been known to fail..The push-on connector blocks can also harbour a multitude of electrical gremlins such as corrosion, poor contact pressure, dry-joint soldering etc...Those mini zip-ties are a god send , aren't they ??....Another area for complete electrical failure can be the contacts on the back of the ammeter as all your electrics flow through there.....Hope your test ride turns out OK ??

[Bertie the Bullet]

Hi Alan R, I will admit I don't know the wiring on a Bullet, do I understand correctly that the while electrical system is dependent on the ammeter working properly, if this fails then so does the electrical system and the bike stops ? , cheers

[Alan R]

Hi BERTIE------- a few years back I went to the aid of a fellow Bullet 65 owner over in Shrewsbury who had ridden his bike home the evening previous with intermittent cutting out..The next morning it wouldn't "power-up" at all....Eventually I found one of the wiring securing nuts on the back of the ammeter had shaken loose and was halfway down the thread !!...Some loctite and re-tighten and all was well again....I'm sure that the Bullet wiring diagram shows that all the circuitry passes through the ammeter, thus a break here would cut all supplies.....

[tsflyer]

Thanks ALAN R for the kind comments! A 100+ mile ride out thru sunset (and a few stops at my favorite taverns)proved to be flawless. I've regained my confidence in her again! Agreed, I'd like to see more follow-up "repair techniques and end-result" postings. That's where these postings prove to be helpful, not the thread just ending with a multitude of repair suggestions...and no result postings. How do we know which has worked for the owners! Anyhow, I still love this forum and read it religiously. Ride on! Tim