Bike makes clicking sound - only starts with Kickstarter with LOW fuel light ?

Hey guys,

I recently framed my 15' 500exc and have only just reassembled the bike. With everything loosely fitted I tried firing it up but no luck. After a brief inspection I saw that I didn't attach the lead to the throttle-body- plugged it in and it started first go.

I then fitted the tank, seat and plastics on properly, but now when I press the ignition I just hear a single click from under the seat (relay ?)

Failing that I started it with the kickstarter and it fired up fine. About 1 minute into the trip the fuel light came on And it began to stall when I gave it any throttle at all- though it seems content to idle very weakly.

I began to think it's due to the fuel pump, but when I check the throttle body side hose it's oozing with fuel, so fuel seems to be getting through to the throttle-body. Even if it was the pump, why would the bike not turn at all when the ignition is used ?

Similarly, if it was the starter (brushes) that doesn't explain the fueling issue once the bike has been kick-started.

I've tested with two fully charged batteries also.

Anyone have any bright ideas ?

Hey thanks for the idea.

I got it going sort of. The volt meter was reading 13v at the starter spade, but only 9-10v at the starter terminal.

It seems the powder coat is preventing a good earth to the frame and engine. I have roughly made the contact points better, but sometimes the bike will exhibit the same issue- but un-tightening and tightening the engine bolts seems to fix it.

Will do it all properly tomorrow and report back with findings. Thanks again man!

Running a ground cable from a starter mounting bolt/nut directlly to the Neg post on the battery fixes it for good. Usually improves starting on many bikes.

+1

I got told the same thing on another forum. I'm going to do just that, but what gauge wire can I use for that, something with very little resistance ?

Also just an update on the frame issue:

I took the engine bolts out and meticulously chiseled off the paint to bare frame- since the engine holes are immaculate it only needed cleaning on the outside engine mounting points to get a solid earth. Now it fires up quite easily and have not had the issue since.

I still plan to fit an earth wire directly to starter/engine. Thanks much for all the good info guys!

Use the same gauge as your battery cables.