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post #1 of 19 Old 03-28-2012, 08:31 PM Thread Starter
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Looking for a part!

Hello there.

My headlights have not been working for about a week now on my 650, and I narrowed the problem to the starter button. I have opened it up, cleaned everything up put it back together and nothing.

If I press down on the starter unit itself (the white enclosure with the 4 wires soldered to the top of it) with my thumb, the lights come on. It's as if the starter contacts are not sitting close enough to the plunger contacts.

Okay, so I open it up and inspect to see that everything SHOULD sit tight. Hmmm. So, I further disassemble the plunger part and pop out the contacts on it. I figure it I pop them out enough, they would touch the starter contacts but now it would seem like I really screwed it up. The bike wont even start when it's all put together. I can start it by closing the circuit on the starter contacts, but thats about it.

I am thinking that I need a new starter enclosure and it would seem as if I need an entire new switch assembly! This can't be the case, right? Is there an alternative? I need help!

Thanks!
-g
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post #2 of 19 Old 03-28-2012, 08:52 PM
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I cannot answer your question regarding if only the starter *switch* is available as a spare-part.

I do know that I used to have a Honda V45 Sabre and to replace the hi/lo beam switch I had to order THE ENTIRE LEFT HANDLEBAR ASSEMBLY for well over $100. Once the dealer told me that, I took it apart and figured out how to fix it.

Let us know how this works out for you....
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post #3 of 19 Old 03-28-2012, 09:40 PM
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Only the entire handlebar switch is available.

Pat- 2007 DL650A was ridden to all 48 contiguous states. I didn't quite make it to 17,000 miles on the 2012 DL650A.
Nicknames I use to lessen typing, Vee = 2002-2012 DL1000s. Vee2=2014-2016 DL1000s. Wee = 2004-2011 DL650s. Glee = 2012-2016 DL650s
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post #4 of 19 Old 03-28-2012, 09:48 PM Thread Starter
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NO!!!


I got the bike to at least start again, but no head lights. If I squeeze the contact together, they work... I used the plastic lid from my humus and inserted it under the plunger for the starter. I have to hold the starter in the right spot for it to start but, at least it starts.

I am going to order it tonight. Seems like a pretty easy swap. I was looking at the throttle cables... nothing too crazy in there is there?

Thanks you two.
-g
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post #5 of 19 Old 03-29-2012, 10:32 AM
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You should install the easternbeaver.com headlight relay kit.
It will direct the current draw through your headlight switch to only trigger relays, not the entire headlight load.
That is quite likely what caused the failure of your switch.

L2V -- she's a stocker!...and gone...
2011 MG Stelvio
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post #6 of 19 Old 03-29-2012, 10:46 AM
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I haven't looked at a starter switch on this bike, but is it possible there are some springs inside that have fallen out or are not in the right position anymore, or possibly broken? Or a metal spring clip that is bent. Something corroded or needs a good lubing?

I would spend a bit more time looking at it before ordering a new unit. WD-40 it maybe?
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post #7 of 19 Old 03-29-2012, 10:52 AM
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Black Lab has a piece on the starter switch but is in transition from here and hasn't gotten up on his site yet. Maybe leaving a comment at Electrical ę Black Lab Adventures can get further info. I seem to remember he had the same issue.

Pat- 2007 DL650A was ridden to all 48 contiguous states. I didn't quite make it to 17,000 miles on the 2012 DL650A.
Nicknames I use to lessen typing, Vee = 2002-2012 DL1000s. Vee2=2014-2016 DL1000s. Wee = 2004-2011 DL650s. Glee = 2012-2016 DL650s
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post #8 of 19 Old 03-29-2012, 11:50 AM Thread Starter
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Thanks guys,

I have been reading through some of BL stuff there. I did exactly as the dr prescribes however, no results. This starter was so clean inside... there was no corrosion - nothing. The top was a bit wobbly though!

So, yea... I have cleaned lubed with dielectric grease and still nothing. The started plunger sits within a white encasing where if I press on top, (where the wires are soldered to the top), everything works. It's as if the entire thing isn't seated correctly - wobbly.

I have thought about getting the relay from EB, but I am not too sure how it could prevent something like this from preventing... I still have no clue as to what has been causing it. Seems like crappy plastic has been ever so slightly bent to cause it. The starter relay is still used when using the EB relay if I am not mistaken so at this point in the game, I don't think it would help.

What I am going to do in the mean time, is solder the headlight to stay on, and just hot wire when I need to start it. It's the only thing I can think of at the moment. I drove the rabbit into work today and I HATE IT. Plus, it was raining today, and I haven't showered for days!

P.S. I just ordered an assembly. I figure I can just solder the new switch when it comes in! 110 bucks shipped - awesome!
-g
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post #9 of 19 Old 03-29-2012, 12:04 PM
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The grease may be part of your problem.
If you get TOO much of it between the contacts, then you can have problems getting the contacts to, well, contact...
Essentially, you want that grease to be most everywhere...
EXCEPT between...
...the contacts.


The relay kit reduces the load on the headlight portion of the electrical circuit only.
The headlight starter switch works as follows:
Key on
Start switch at rest -- power to lights through light contacts - NO power to starter circuit
Start switch pressed -- breaks power to lights (LIGHTS OFF) - power to starter solenoid/relay (the relay contacts the large current draw to the starter)
Let go of start switch -- power back to the lights - open circuit to the starter solenoid

So...
Every time that you hit the starter button, you break, and make contact with a fairly decent current draw directly across those little terminals--because the power to the headlamps runs directly through the headlight portion of the starter switch.
The headlight relay reduces the current across those terminals because it is now (like the starter portion of the switch) only providing power to the relay.


.

L2V -- she's a stocker!...and gone...
2011 MG Stelvio

Last edited by henerythe8th; 03-29-2012 at 12:22 PM.
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post #10 of 19 Old 03-29-2012, 12:46 PM Thread Starter
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Could have too much current going through the terminals cause something within to bend/misshape and distort the use of the starter?
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