Hey guys, I was out moose hunting last weekend (no luck yet) and had some problems with my start in gear feature. It would only work about 1/2 the time, otherwise I had to put her in neutral and start it up. Not that big of a deal, but I really like that option. Before I dig into the problem do you guys have any idea where I should start? I am still under my two year warantee, but with the $50 deductable I am sure I fix it myself.

 

There's gotta be a switch somewhere that senses if you have the break depressed. I'd look for that.

 

Also, from reading my service manual, there should be a Start in gear relay. Directly from the 650 manual, it may or may not help you:

Neutral Start/Front Drive Actuator/Start-in-Gear/Differential lock Relays.

The relays are indentical plug-in type located on the power distribution module. Relay function can be checked by switching relay positions. The relays are interchangeable.

NOTE: The relay schematic is embossed on the relay housing for testing continuity.

NOte: The module and wiring harness are not a servicable component and must be replaced as assembly.

 

Thanks Kylersk for the fast responce, I will check it out.

 

I'm just guessing, but if it's the brake switch, your brake lights wouldnt work when you couldnt start the bike in gear.

 

My 650 did the same thing while under the 6month warranty. They had to replace some type of harness that ran to the brake light, the foot pedal, and then to the hand brake to tell the bike the brake was depressed to allow it to start in gear. They told me the wiring ran down the frame so he had some plastic off and possibly the tank, or so he said??? It was a comon problem, the harness was on back order at the time my bike was down like a month but that was in February or March of 04. I hope this helps in some way! IT is a handy feature so good luck!

 

The switch under the hand brake quite working on my 650. The brake light wasn't working also. Seems like the start in gear would work if I used the foot brake, but can't remember for sure. I know that there was several of these switches went out on the 650's.

 

Man, looks like this could be some work, why couldn't you guys just tell me that all I had to do was tighten a bolt and that would fix the problem! [img]i/expressions/face-icon-small-happy.gif[/img]

I will check it out this weeked, thanks guys for the help!

 

on the right side of quad there are two diodes in the harness. if you look behind the plastic about even with the engine. they plug in simiar to a fuse. on a friends 03 400i that wouldnt star in gear he had to replace one of these. odd thin was he could replace either one with a new one and it would start but with the two originals it wouldnt. hope this helps.

 

the part # is 0486-029