Hey guys I need help. I just put the transmission and engine back together last night in my 2nd DS650 (2005). It had no first gear when I got it, so I tore it down and replaced the shift forks and had Mr. HP (Eric) reverse cut the gears. I also installed a new 12-1 Piston and new cams.
Anyway I went out to the shop today to fire it up for the first time and it won't turn over. What I mean is all that happens it the starter solenoid just clicks. So far I have taken the starter out and bench tested it - tested ok, I cleaned all the battery terminals and made sure the battery is up to par - all good. I removed the starter solenoid and cleaned all the terminals. - Still getting the same result. The manual told me to test the solenoid with a volt meter and I believe it directed me to the ingition module (Rev Box).

I have never seen a rev box fail like this. I was going to swap in my extra one from my 2000 DS but of course it has a differnt plug.

Any ideas ?? I really want to get this bike fired up and broken in before we head for the dunes in a couple of weeks. Any help would be appreciated.

 

You didn't happen to leave the TDC bolt in the crank did you? Maybe a bad ground to the engine,

 

Definitely check your ground on the frame. Six years old now and it may have some corrosion in the area.

 

With 1 spark plug removed and in gear.
Can you turn the motor over easily by turning the rear wheel.
If everything seems tight, on the right side, remove cover and note the position of the
washer on shaft to gear that the starter turns.
If in wrong position, when cover is tightened, will not allow the starter to turn.

OMR

 

Should have also said that I removed the starter (still had power wire hooked up) and grounded it to the engine and hit the starter button and still had the same result - no starter engaugement - just a click from the solenoid.

I did double check to see if I had the TDC bolt still in - I was really wishing it was that simple.

I have not checked the ground cable yet - looked at it and it looked clean, but will remove it today and make sure.

 

I did have a solenoid go bad last season out at Glamis. Same symptoms you describe. Pulled one off of the back up bike and all was well for the rest of the trip. Picked a couple up from ebay upon my return for next to nothing and still working well. Always carry a spare in the toolbox now. Low cost insurance for our machines that are getting older now.

 

I am going to remove the one off my other bike this morning and try it. I never heard of a solenoid going bad - but there is a first for everything.

Thanks Ace

 

Removed the good solenoid off the other bike - still same result. Cleaned all the wires and grounds again - still same result.

I removed 1 spark plug and managed to turn the engine over about a revolution, so thats a good thing - engine is not stuck.

The manual says I should suspect the rev box (module). Has anybody heard of a rev box causing this problem ?

 

I "assumed" that the voltage has already been checked. If not it should be 12v+ with key off, when you hit the start button the voltage will drop to around 9v +/- .25v, then when the bike starts your voltage should read in the 14.25v range.
Are you dropping below 9v when this clicking is going on??? Normally a bad CDI will give you sputtering and popping while running as it controls spark, doesn't usually affect starting the bike.
Did you try the solenoid that you removed on the bike that does run? Might as well since it's off already.

 

Update: It is fixed and running. Had good buddy come over on Saturday with multi meter and help me do some tracing. I was only using a test light before. We traced a hugh voltage drop on the way to the starter. The starter and wires were even getting warm. I pulled the starter again to gheck it - still hooked to the bike. Grounded it this time with a set of booster cables - and it worked. Last time I just held it to the motor. The reason my test light was not lighting at the starter was we had only 3 volts - not even enough to light the test light.

This made think OMR post about having the washer and bushing in the wrong place. I tried to turn the started gear by hand and a screw driver and they were both stuck tight. I pulled the side cover off and sure enough I had the bushing on one shaft and the washer on the other. I thought I paid close attention to that part but i guess not. After putting the bushing and washer on the same shaft the starter gear moved freely.

After reasembley she fired up on the first turn. Even has all the gears after the tranny rebuild.

Thanks OMR - I would have been looking for this problem for weeks. I owe you a few beers for sure.

Thanks to all the forum members who replied - not sure what I would do without you guys.

Thanks Again Guys