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Buell Forum » Knowledge Vault (tech, parts, apparel, & accessories topics) » Troubleshooting (Poor Starting/Running/Handling/Ride Issues) » 99 S3 shutting off randomly « Previous Next »

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Newmans3
Posted on Monday, May 18, 2015 - 08:37 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

So the last 2 times I drove it to work before this weekend, as I was parking it, with the clutch lever pulled, not in neutral, kickstand still up, engine would just shut off.
After work, started right up, drove home with no issues.
This weekend on a long group ride, we pulled over to discuss the end of our route, shut bikes off.
Started her up to leave, shut off immediately.
Restarted, shut off again.
No engine warning light or gas light on.
Then start button would do nothing.
Many times turning key on and off, noticed the fuel pump would sometimes prime, sometimes not.
Checked for loose wires at the battery and going into the fuel pump, no obvious issues.
Eventually started and stayed running, rode home about 20 miles, ran well with no issues.
At home, turned key on and off, every time the fuel pump primed, started it a few times, stayed running, again, no issues.
Any one have any ideas?
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Dave
Posted on Monday, May 18, 2015 - 08:53 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Sidestand safety switch?
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Newmans3
Posted on Monday, May 18, 2015 - 10:19 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Didnt think of that.
Issue happened with kick stand up and also when it was down.
Would that switch prevent the fuel pump from priming?
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Dave
Posted on Monday, May 18, 2015 - 11:51 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I can't say for certain - someone else will need to weigh in. I bypassed my 1999 Thunderbolt's about 15 years ago when it gave me fits on a trip.

DAve
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Akbuell
Posted on Monday, May 18, 2015 - 04:14 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

The ign shuts off if not grounded 1-Through the neutral switch 2- Through the clutch switch if not in neutral 3- Through the sidestand switch if the sidestand is up, in gear, and clutch out.

Unplug the switch, and jumper the two female (wiring harness side) connectors together. If the problem goes away, the sidestand switch was the problem, and you can install a permanent fix. I think I used a 1/4in female blade connector and silicone seal.

Is there the possibility of a chaffed/broken wire in the steering stem area?

Finally, PM me and I can hopefully show you a way to bypass the ign switch, and eliminate/confirm another possible trouble area.

Hope this helps, Dave
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Newmans3
Posted on Monday, May 18, 2015 - 04:32 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Thanks Dave, great info.
PM sent.
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Akbuell
Posted on Monday, May 18, 2015 - 08:35 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

PM replied to, if I did everything right, LOL.
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Newmans3
Posted on Tuesday, May 19, 2015 - 08:11 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Nothing yet Dave.
My email is
michaelweis99(at)gmail(dot)com
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Akbuell
Posted on Tuesday, May 19, 2015 - 09:37 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Tried again.

Dave
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Akbuell
Posted on Thursday, May 21, 2015 - 10:25 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Made a couple of different attempts at sending info. Let me know; if not good, will try something different.
Dave
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Newmans3
Posted on Thursday, May 21, 2015 - 02:18 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Got the last one Dave, thanks for making sure it went through, will try installing that this weekend.
Mike.
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Akbuell
Posted on Friday, May 22, 2015 - 07:58 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Excellent! Please let us know how it goes.
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Newmans3
Posted on Sunday, June 07, 2015 - 01:14 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Finally dug into this issue today because when I went to start, nothing.
Found this ignition switch wire damage behind the headlight.


Fixed but still nothing, all lights work when ignition is turned on, fuell pump does not prime, starter does not do anything when switch is used.
Fuses are good.
I am about to bypass sidestand switch as Akbuell suggested, then to bypass ignition switch as Dave instructed (but I'm not totally confident in my electrical system abilities).
Also had a new clutch lever switch to install, that didn't help, just did it cause I had one.
Any other suggestions in the meantime?
What would the ignition wire damage/short affect?
Thanks everybody.

(Message edited by newmans3 on June 07, 2015)
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Newmans3
Posted on Sunday, June 07, 2015 - 01:58 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

How do I even get to the side stand connector to bypass it?
It is wedged between the frame and the oil tank!
Not enough slack to move toward rear tire, no room to move it forward.

(Message edited by newmans3 on June 08, 2015)
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Newmans3
Posted on Sunday, June 07, 2015 - 02:23 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)



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Newmans3
Posted on Sunday, June 07, 2015 - 02:32 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

In terms of electrical troubleshooting both issues...
What prevents the fuel pump from priming when key is turned on?
What prevents starter from working when button pushed?
Is there a common fuse or breaker or relay?
If one doesn't work, is the other disabled?

(Message edited by newmans3 on June 08, 2015)
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Newmans3
Posted on Sunday, June 07, 2015 - 03:51 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Bypassing sidestand safety switch did not help.
Bad fuel pump?
Would that cause starter to stop working?
Or would blown relays or solenoids do this?
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Newmans3
Posted on Sunday, June 07, 2015 - 04:21 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Bad kill switch maybe?
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Newmans3
Posted on Sunday, June 07, 2015 - 05:08 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Just noticed the Check engine lamp NOT illuminated at Key On, supposed to be on for 4 seconds, right?
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Newmans3
Posted on Sunday, June 07, 2015 - 07:43 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

The service manual has me going in circles.
Anybody have any thoughts?

(Message edited by newmans3 on June 08, 2015)
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Akbuell
Posted on Monday, June 08, 2015 - 10:16 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

E-mail(s) sent.

Dave
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Newmans3
Posted on Tuesday, June 09, 2015 - 09:18 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Dave,
Charged battery fully, no change.
Any suggestions for next steps?
Thank you again.
Mike.
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Newmans3
Posted on Wednesday, June 10, 2015 - 07:26 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Dave,
Followed your instructions, this is what I have found...

Fuse block:
12V @ inst fuse
12V @ lights fuse
No voltage @ ignition fuse station.

Relay Block:
Tested Diodes, both are good.
Swapped Relays with no change.
No volts @ pin 30 when the red probe was in pin 30 socket and the black one in pin 86 socket.

Not sure where that puts us, I'll wait for more instructions.
Thanks
Mike
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Newmans3
Posted on Sunday, July 05, 2015 - 12:32 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Man, next time I will take the tank off sooner, found a connector under the tank had vibrated loose giving these random issues.
Back together and all zip tied to prevent it from happening again.
Runs great and ready for the road.
A big thank you to akbuell, who was extremely helpful and very patient, thank you for the guidance, I really appreciate it!
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Akbuell
Posted on Sunday, July 05, 2015 - 10:11 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

You are very welcome. Glad to be of help.

And thanks for the update and solution. Helps the 'community knowledge'.

Dave

(Message edited by Akbuell on July 05, 2015)
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Dave
Posted on Sunday, July 05, 2015 - 06:22 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Alright! Happy ending.

DAve
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Newmans3
Posted on Monday, July 06, 2015 - 12:37 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Thanks also to DAve for help on this.
I appreciate your time.

Gotta say, this site is a great tool to keep these beauties going strong.
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Bagmann60
Posted on Friday, August 14, 2015 - 07:43 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

1999 S3

Bike was running fine 5th gear about 60 mph. Suddenly revs reduced, running very rough and back firing. everything (speedo,tach, lights) dead except check engine light and clock. shut down bike with master and key.
attempted restart but nothing is powered except the clock. Clock stops when key is turned to ignition setting.
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Ocbueller
Posted on Friday, August 14, 2015 - 08:55 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Sounds like key ignition switch.
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