[zoolander]

Does anyone know what this relay does(white one)? When I engage the clutch, it makes an audible click sometimes (maybe 50% of the time).



This is a close-up of the right side of the bike

This is panned out a bit

Thanks, Gordon

 

[Dave Nafziger]

Gordon-

It looks to me like the starter cut-off relay. It has a wire directly from the mommy switch on the clutch lever.

Another wire goes to the bigger relay (solenoid.)

My 89 has another, the ignition circuit cut-off relay, just forward of it. Check the circuits in the manual when you get a chance;

let us know. Any other symptoms involved?

GB

 

[zoolander]

I checked the parts manual and 29U-81950-93 simply says "Relay Assy". I couldn't find anything in the service manual specifically referencing that part no. I can't read electrical/wiring diagrams so it's probably in there but I wouldn't know.



I was looking at this part because I'm having an issue with my neutral light. I turn the ignition on and all the lights go on, including the neutral light(when in neutral). The bike will start but after a while, the neutral light will flicker off. Sometimes the bike will die, sometimes it remains running.



If it dies, I can hit the starter and sometimes it will start, sometimes it won't. When it does not start, an audible click will come from this relay. I can not find any obvious loose connections anywhere. I looked closely at the clutch lever switch (next to the clutch cable) at the left handlebar but I can jiggle that pretty good and the neutral light does not seem to be affected.



?!?!?

 

[Dave Nafziger]

Next time it refuses you, tap the outside of the case of the solenoid with the starter button in lightly with a small hammer or wrench. I think the connection inside is crumby. Next,try jumping it across the main posts at the solenoid, the main starter relay. This is where the red from the battery is bolted on, in your picture above, and you are jumping to the heavy lead that goes to the starter. These are about an inch apart. You eliminate all safety switches, including the key, so be sure it is in neutral. It will crackle a bit, as if you were jumping a battery. A short piece of 10 or 12 gauge wire with the insulation peeled back from each end works great, but less fancy things do also.

 

[FortPayne]

Hey you and teedubs should get together. His neutral switch/starting system is giving him fits here. Sounds like the neutral switch is going to me. Either that or there is a short on one side of that relay. I think the relay is working fine, if I remember correctly they are supposed to click when activated.



When your bike dies after the light flickers off will it start back up when you hold in the clutch? If your bike no longer knows its in neutral it will kill the engine without the clutch in and kickstand up. Next time it does it try eliminating both and see if it fires right back up.

 

[Dave Nafziger]

My thinking is that the relay he showed us should click because it the nature of that switch, and that solenoids do even more so because they are

bigger switches with bigger electromagnets. The little tap idea is because whereas they may be switching on, the contacts inside may be pitted past the point of always carrying current. A jar on the onside of the case has wiggled the inside enough to realign contacts to carry electricity many times for me, and on different sorts of machines.



But I would go along with the neutral switch idea as well. BTW, does the neutral light ever glow dimly, especially noticeable at night, when it shouldn't? The starter cut-off relay has a diode in it to keep electricity from back-feeding to the neutral light. I think if either the switch

is bad, or the diode in the relay, the light will come on. Mine light got brighter and brighter; then the starter quit starting sometimes,

and then never did.



GB

 

[FortPayne]

Learn something new everyday! I didn't know about the diode and possible pitting of the relay/solenoid.



I was just thinking as to why it would die in the first place. Do neutral switches often go bad?

 

[TeeDubs]

Hey you and teedubs should get together. His neutral switch/starting system is giving him fits here. Sounds like the neutral switch is going to me. Either that or there is a short on one side of that relay. I think the relay is working fine, if I remember correctly they are supposed to click when activated.



When your bike dies after the light flickers off will it start back up when you hold in the clutch? If your bike no longer knows its in neutral it will kill the engine without the clutch in and kickstand up. Next time it does it try eliminating both and see if it fires right back up.

My issue is I can't get the bike to start.... Absolutely nothing happens when I click the starter........ I know the bike has to think its in neutral to engage the starter...... But if you jump the solenoid you should still get spark and the bike should still run even if the neutral switch is bad (bike has to run when it's in gear right?)



My bike might be fubar because I don't get a spark when I jump the solenoid... I don't even get a neutral light at all

 

[zoolander]

Thanks for your replies so far guys. I tried the tapping of the solenoid, among other areas too. I have been tugging on this wire and that wire, but I can't reproduce the neutral light going out. It doesn't get dimmer nor does it get brighter...it just flickers quickly and goes out...then comes back on 1. when you gently jiggle the gearshift lever(sometimes) or 2. whenever it feels like. The weird thing to me is that even when the neutral light flickers out, the bike sometimes won't die. It just keeps running as if nothing else happened. Nothing really follows a consistent pattern either, sometimes it will die, sometimes not.



I think I'll just replace the neutral switch because that sounds easy and reasonably priced enough. I'll keep you guys posted, thanks again.

 

[Omega Man]

My issue is I can't get the bike to start.... Absolutely nothing happens when I click the starter........ I know the bike has to think its in neutral to engage the starter...... But if you jump the solenoid you should still get spark and the bike should still run even if the neutral switch is bad (bike has to run when it's in gear right?)



My bike might be fubar because I don't get a spark when I jump the solenoid... I don't even get a neutral light at all

I would try push starting the bike and see if it will run..That is after seeing if the battery has a charge.

Thanks for your replies so far guys. I tried the tapping of the solenoid, among other areas too. I have been tugging on this wire and that wire, but I can't reproduce the neutral light going out. It doesn't get dimmer nor does it get brighter...it just flickers quickly and goes out...then comes back on 1. when you gently jiggle the gearshift lever(sometimes) or 2. whenever it feels like. The weird thing to me is that even when the neutral light flickers out, the bike sometimes won't die. It just keeps running as if nothing else happened. Nothing really follows a consistent pattern either, sometimes it will die, sometimes not.



I think I'll just replace the neutral switch because that sounds easy and reasonably priced enough. I'll keep you guys posted, thanks again.

Of course I'm not there but a faint glow or flicker or what you describe sounds like a bad/loose ground. It could even be a loose battery cable condition. Like above, it's nice to start with a good battery charge.

 

[TeeDubs]

Thanks for your replies so far guys. I tried the tapping of the solenoid, among other areas too. I have been tugging on this wire and that wire, but I can't reproduce the neutral light going out. It doesn't get dimmer nor does it get brighter...it just flickers quickly and goes out...then comes back on 1. when you gently jiggle the gearshift lever(sometimes) or 2. whenever it feels like. The weird thing to me is that even when the neutral light flickers out, the bike sometimes won't die. It just keeps running as if nothing else happened. Nothing really follows a consistent pattern either, sometimes it will die, sometimes not.



I think I'll just replace the neutral switch because that sounds easy and reasonably priced enough. I'll keep you guys posted, thanks again.

I'd try checking the connection to the neutral sensor, on my bike it's the sky blue wire that comes off the ignition circuit cut off relay (Close to the battery under the seat)... it's just a simple plug typle connector if it's loose... could be an easy fix



The neutral sensor just grounds into the bike... I'd also check your indicator bulbs and connections



Here's a picture of the neutral sensor, you have to take the whole left side engine cover to get at it... witch will mean an oil change and new gaskets

 

[TeeDubs]

I would try push starting the bike and see if it will run..That is after seeing if the battery has a charge.

I wish it were that easy! I have been able to jump the solenoid and get the starter to engage... but there's no spark



check out this post, it tells everything i've done to my bike so far to diagnose the issues... still a work in progress but I think I'm learning alot about our beloved TW's



http://tw200forum.com/index.php?/to...7-tw200/page__st__30__gopid__38482#entry38482