rockster not starting

[ssardone]

I did a search but can't find anything-I remember reading about the wiring bundle on the rockster being zip-tied too tight near the bars, ignition switch, etc. My son has an '04 Rockster and last week it started not starting. After I checked numerous things out I remembered reading about the wiring problem so I started moving the bars back and forth while holding the starter button and it started. I clipped numerous wire ties to loosen the bundle of wires. It has been starting for several days as long as the bars are moved while holding the button. This afternoon it will no longer start but the starter motor is spinning the engine just fine. I know I read about some of you rockster owners having the same problem. How did you fix the problem and was there any specific wire that seemed most vulnerable to the problem? Thanks for your help.

Steve

[ssardone]

can anyone at least tell me if this sounds familiar? Did I read this on another forum?

thanks

Steve

[NoRRmad]

I ride a Roadster, but it certainly sounds familiar. Usually recommended is to remove or loosen the tie-wraps for the electrical wires near the steering head, but since your trouble is already happening, a pull-apart of the wiring harness in that area, with a close inspection of the individual wires should reveal where the trouble is. Strip back the insulation, solder in a bridge wire and start 'er up.

Not a fun job, but WAY cheaper than the dealer solution, which is a new wiring harness.

[ssardone]

We pulled the tank off yesterday and clipped many wire ties and inspected all the wires-nothing found. Bike still won't start so I guess I will start stripping away the heavy black covering for the wires and see what is visible. thanks for the help.

Steve

[NoRRmad]

Since the starter is working, but the motor won't actually start, it sounds like the kill-switch wire. Can you make the motor die by wiggling the handlebars? Are you starting in neutral, or in first with the clutch in?

[ssardone]

Saturday it started numerous times while wiggling the handlebars. It has never stalled after starting. Can't check any further til I get it started. Have attempted starting mostly in neutral but also with clutch in while in gear and in neutral, side stand up. I'll concentrate on the kill switch.

thanks

steve

[rantee]

Did you by chance move or touch the throttle cable adjuster at the engine? If the throttle cable guide came unseated from the adjustment ferrule, the bike won't start. A quick visual will tell.

[ssardone]

both sides seated properly-thanks

steve

[harrisphil]

have you checked the basics
has the engine got fuel and sparks?

[ssardone]

that is what I was checking the day I discovered that it would start by wiggling the handlebars. I was not getting any gas or spark and I have to assume that there is something in the wiring harness that is cutting off the fuel and spark. I was getting no gas or spark and I got it to start by wiggling the bars. Am I making any sense? When I turn the key on I could hear the fuel pump running but the plugs were dry and I got no spark when I grounded the plug against the engine. Then I put the plug back in and got it to start by wiggling the bars. thanks for any thoughts.

Steve

[boxermania]

ssardone

You have an issue with the wiring to the kill switch. You will need to trace the wires from the switch back into the wire bundle and look right around where the nylon tie wraps wrapped, right behind the steering head. You will have to slice open the cover to the wire bundle. There will be some broken or about to be broken wires that make contact intermitently.

Good luck and keep us informed.

[robclare]

Hi there,

I may be late, but am just fixing the very problem you have.

Trace the lead from the base of the ignition switch approx 2 1/2 inches back to the base of the sterring head.
Slice open the outer cover where it's cable tied and does a 90deg turn.
revealed will probably be a broken wire or more (3 on mine).
Solder the ends back together and insulate, then tie wrap not so tight as the monkeys from bavaria-away you go....

Rob

[ssardone]

I will go back and check that specific area. I did slice open the outer cover on numerous bundles and never found a broken wire. After doing some other research I decided to pull the starter and have it rebuilt. Upon reinstalling it last friday it started right up and has started immediately ever since. I can't explain it but it is working great now. The symptoms I had don't seem to have lead to a starter problem but that did it. I guess it is possible that I did have a broken wire(and still might) and I jiggled it during all my fiddling in there and will have it reappear in the future. Anyway thank you for all the replies and suggestions.

Steve

[Kobe22]

Threads never die... they just go on sabbatical... anyway by way of resurrection... my Lime-girl stopped dead in the middle of rush hour traffic on 495. \

4,000 miles on her... zero modification..... even has crappy QC's on it still!

I was PISSED!

Had to tow her home... now she sits pretty completely useless to me in this tropical weather!

Beemer-bots please advice...

[NoRRmad]

Ran out of gas?

[sweatmark]

my Lime-girl stopped dead in the middle of rush hour traffic on 495.

Symptoms?
What's it doing (or not doing) now when attempting start back in your garage?

[Kobe22]

Symptoms...

Red oil lamp is on. It appears to have enough juice to turn over. Never fires up, if persistent will keep turning till the battery drains.

@NoRRmad : filled her up the previous morning, oddly enough I had seen the fuel shortage indicator but she only gulped a little over 3 gallons.

I'm stumped .

Any diagnostic methods or techniques will be greatly appreciated

[omg1010]

As said earlier in another post, you need to check the basics (fuel supply and spark). If both is fine (you have to check if fuel gets injected and not only that your tank is filled) it maybe some electrical problem (wiring around the steering head). Does the engine crank and not fire up or does nothing happen when you push the starter button?

Brgds
Oliver

[Kobe22]

Sorry but I have no idea how to check for spark . The engine does crank but doesn't fire up. I read a number of posts on the 'wiring around the steering head' as a possible cause but have since inspected and not seen any visibly obvious strains in the wiring in the 'neck' of the bike.

[robclare]

We pulled the tank off yesterday and clipped many wire ties and inspected all the wires-nothing found. Bike still won't start so I guess I will start stripping away the heavy black covering for the wires and see what is visible. thanks for the help.

Steve

The problem area (for me) was at the base of the steering head on the left of the bike as you sit on it.
Due to tight cable ties, the wires had fractured due to bending as you turn the bars.
I found one broken wire and two more about to go.
My problem was cutting out as I turned right.
Hope this helps,
Rob