Random No Start

[Batfink]

Hi Everyone,

I've got a random no start on my 2009 R1200GS Adv, so thought I'd try the collective minds of everyone here.

Symptoms are:

1. All ok on the dash (no EWS etc.)
2. New Battery fully charged
3. Press Start button, and I sometimes get a single loud clunk from the starter motor (definitely starter motor, not just a quiet click from relay), but no cranking

Sometimes it starts first time on the button, other times it can take maybe four goes on the button before I get it to crank.

I've had the tank off yesterday just to check the relay for signs of corrosion and it's all good and clean under there, no corrosion on the connectors. (next time I won't fill the tank just before doing this ).

I also tried positive from battery to -ve on Starter Motor and it cranks properly, but then again it's random on the button so could have just been lucky when I did this.

Any ideas?

Cheers

 

[Mistacat]

I have known the wire that runs from the relay to the spade connector on the starter break.
Leave the old wire in place and run a new wire to test it.
I assume that you have bridged the starter motor ( positive wire from the battery on the starter to the spade terminal with an old screwdriver) just to show the starter is ok and to get the bike running.

 

[Smiffypr]

If the solenoid (part of the starter motor) clunks but the starter doesn't turn the engine, but it doesn't chatter (which would suggest a flat battery or bad battery connection), my guess would be the contacts in the end of the solenoid are worn/burnt.

 

[Pukmeister]

Could also be worn starter brushes/dirty commutator if starter is engaging on the solenoid but the windings aren't getting power through them.

The starters are worth stripping down to clean, and lubricate the epicyclic gearing whilst apart as they can gum up with dust and old grease.

You can buy a new set of replacement brushes and brush holder cheaply enough online, I believe these are the correct ones but do your homework first if buying a set:

https://www.autodoc.co.uk/bosch/707286?utm_medium=cpc&utm_source=google&tb_prm=20315908947&gshp=1&gad_source=1&gclid=CjwKCAjwp4m0BhBAEiwAsdc4aN91DYthsJqgC04g3iX6p0k_zZOz1QKgxqnCZYI-KkUbE2VprwJf-BoCK2IQAvD_BwE

 

[Batfink]

Thanks everyone, I'll try each of those things and see where I get to. At least it still works and I've got a spare piece of wire that I keep in the top box, so I can start via the battery and starter motor directly if needed.

I think stripping down the Starter Motor will be a good thing to do anyway, as I've not done any maintenance on the starter since I bought the bike new in 2009. (Thanks for the link Pukmeister)

Can't complain I guess seeing as I've had it for 15 years with no problems at all.

 

[Batfink]

So I stripped down the starter motor today and it all looked pretty spotless and the brushes looked in good nick too. Cleaned it all out anyway, re-greased all the bits that looked like they needed it and sanded down any contact points and put it back together.

I've been out and tried starting it 3 times today and it's started first time each time, so I guess I'll just wait and see how it goes.

Cheers everyone

 

[dashfixer]

If it starts ok using a jump wire then it's not the starter. Go for wiring like Mistacat says.

 

[Batfink]

I have known the wire that runs from the relay to the spade connector on the starter break.
Leave the old wire in place and run a new wire to test it.
I assume that you have bridged the starter motor ( positive wire from the battery on the starter to the spade terminal with an old screwdriver) just to show the starter is ok and to get the bike running.

Looks like I’ll be getting the tank back off again when I get a chance, to look at that wire to the spade connector. The bike did the one loud click from the starter again today after stripping and cleaning it yesterday, then started as normal on second try.


Sent from my iPad using Tapatalk

 

[seahorse]

Given the age of your bike I would also recommend having another look at the wiring to the relay. I had a pile of green dust on top of the motor and the red wire completely separated from the terminal. Re made all four while I was at it just to be sure. If you're really keen you can get the correct terminals that fit into the relay connector block from any BMW car dealer, thread about this somewhere, they are only about a quid each . And yes better to have an almost empty tank! I ran mine for a week using a screwdriver across the starter terminals to run the tank down before doing the work.

 

[Batfink]

Given the age of your bike I would also recommend having another look at the wiring to the relay. I had a pile of green dust on top of the motor and the red wire completely separated from the terminal. Re made all four while I was at it just to be sure. If you're really keen you can get the correct terminals that fit into the relay connector block from any BMW car dealer, thread about this somewhere, they are only about a quid each . And yes better to have an almost empty tank! I ran mine for a week using a screwdriver across the starter terminals to run the tank down before doing the work.

Yes I'll be taking it all apart and looking at every connector, however I must say I was amazed just how clean everything looked when I took the tank, ECU, and Relays apart the other day. No corrosion on anything (I have always washed and dried the bike whenever it's gotten wet or after any trips), no green dust anywhere and the relays just had a bit of dust on them and their connectors were spotless. Hopefully it's just a bit of a dodgy wire to the spade connector, that I can rewire.

The main thing is the bike is still working fine and doesn't hinder me using it, apart from having to push the start button more than once every now and again.

 

[Bigcats]

Yes I'll be taking it all apart and looking at every connector, however I must say I was amazed just how clean everything looked when I took the tank, ECU, and Relays apart the other day. No corrosion on anything (I have always washed and dried the bike whenever it's gotten wet or after any trips), no green dust anywhere and the relays just had a bit of dust on them and their connectors were spotless. Hopefully it's just a bit of a dodgy wire to the spade connector, that I can rewire.

The main thing is the bike is still working fine and doesn't hinder me using it, apart from having to push the start button more than once every now and again.

Isn't this then pointing towards something like the starting relay??

 

[Batfink]

Isn't this then pointing towards something like the starting relay??

I would have thought the relay would either work or it wouldn't ? Not random no start every 1 in 5 times I push the starter button. (or perhaps I'm wrong?)

(When I say dust on the relay, I literally meant a bit of road dust)

 

[seahorse]

You can swap the spot lamp relay to check. I don't have one myself but checked with another spare

 

[Batfink]

You can swap the spot lamp relay to check. I don't have one myself but checked with another spare

Yes good idea, I'll do that and see if it has intermittent start or not.