Oh please help...

Forgive my ignorance, but I would love to start my 1997 Intruder 800.  I know some limited things about the electrical system, but I'm stuck.

I previously modified the wiring to accommodate the ape hangers I installed, and was fine last year before winter.  And I've done it before, as I have a 94 Intruder 800 as well that I modified.  So I got new (used) wiring (the right side handlebar pod with start button) from ebay, snaked it though my ape hangers and connected it to the old connections.

The battery is good and new and charged.  Fuses are fine.  Turns signals are fine, headlight and taillight OK.  I bypassed the safety clutch lever switch - I just can't get it to start.

I can jump start it at the starter relay by touching the wires together, so I think that tells me the relay, ignitor and ignition coils are fine, but the wiring may be bad?  If so, where?  or is it my start button? 

I do have a multimeter, but I really don't know how to use it very well.  

Help?

Did the wiring set you bought come from a model of the same year ?  They sometimes make slight changes to the wiring - the connectors fit, but connect to different things on the other side.  If you still have the wiring you took off, refit that & see if it starts.  If it does, trace the wiring colours against the replacement - a wiring diagram would help you here.  If you have a wiring diagram, you could run the probe along the connector from the started button to see if you're getting feed

No it did not but most intruders wiring hasn't changed (much) from 88 to 2004 or so.  I have a Clymer's and the actual Suzuki repair manual, which makes my problem adds to my shame.  I've followed the wiring diagrams in both books carefully, so I don't think its my wiring but maybe the condition of the wires or defective parts, or ground wires?  Or something else that I'm missing?   I don't know how to run a probe.

You say "I can jump start it at the starter relay by touching the wires together, so I think that tells me the relay, ignitor and ignition coils are fine, but the wiring may be bad?  If so, where?  or is it my start button?  "
Does this mean the starter relay is OK ?
....the relay coil will  be connected to earth on one side and get a live coming from the starter button when pressed. Is the live getting there ? is the earth good ?....somewhere to begin ...

MikeKKim wrote:

No it did not but most intruders wiring hasn't changed (much) from 88 to 2004 or so. 

When I swapped my switch gear out to have them sprayed, I found that the replacement set (from a different year) would not work.  The L/H side was fine, but as they'd removed the option of side lights, the other side (with the starter) didn't work as they'd changed the wiring in the connector.  Try reconnecting the starter button to your system - you don't need to refit the whole lot.  If the bike starts, then it's associated with the new starter, if it doesn't, then it's a problem further down.

To test for feed, you don't need to learn how to use a multi-meter - you only need a simple circuit tester which lights up when you're getting feed.  One end grounded on either the frame or the batter, the probe into the wire connector that you're testing.  If it lights, you're getting feed.  

yorky wrote:

You say "I can jump start it at the starter relay by touching the wires together, so I think that tells me the relay, ignitor and ignition coils are fine, but the wiring may be bad?  If so, where?  or is it my start button?  "
Does this mean the starter relay is OK ?
....the relay coil will  be connected to earth on one side and get a live coming from the starter button when pressed. Is the live getting there ? is the earth good ?....somewhere to begin ...

I think the relay is ok - I had bought a another used one off ebay ("guaranteed to work") and connected it but it had the same non-response - I don't know how to check the power getting there, though I found some ways from other forums of doing it but they use a multimeter which I don't know how to use properly (yes - eventually I will learn to use one)

katsd wrote:

MikeKKim wrote:

No it did not but most intruders wiring hasn't changed (much) from 88 to 2004 or so. 

When I swapped my switch gear out to have them sprayed, I found that the replacement set (from a different year) would not work.  The L/H side was fine, but as they'd removed the option of side lights, the other side (with the starter) didn't work as they'd changed the wiring in the connector.  Try reconnecting the starter button to your system - you don't need to refit the whole lot.  If the bike starts, then it's associated with the new starter, if it doesn't, then it's a problem further down.

To test for feed, you don't need to learn how to use a multi-meter - you only need a simple circuit tester which lights up when you're getting feed.  One end grounded on either the frame or the batter, the probe into the wire connector that you're testing.  If it lights, you're getting feed.  

Thank you this is helpful - I will try it soon!!!

katsd wrote:

MikeKKim wrote:

No it did not but most intruders wiring hasn't changed (much) from 88 to 2004 or so. 

When I swapped my switch gear out to have them sprayed, I found that the replacement set (from a different year) would not work.  The L/H side was fine, but as they'd removed the option of side lights, the other side (with the starter) didn't work as they'd changed the wiring in the connector.  Try reconnecting the starter button to your system - you don't need to refit the whole lot.  If the bike starts, then it's associated with the new starter, if it doesn't, then it's a problem further down.

To test for feed, you don't need to learn how to use a multi-meter - you only need a simple circuit tester which lights up when you're getting feed.  One end grounded on either the frame or the batter, the probe into the wire connector that you're testing.  If it lights, you're getting feed.  

OK my circuit tester lights up so I'm getting feed...So what does that me?

That comment should have read - "So what does that mean?"  IF I can jump start the starter relay with touching the big wires together and my circuit tester lights up at the fuses, what does it mean?