on my honda trx 500 we have no power to the ignition switch for starting or ignition

we have lights and horn working

all fuses are fine

have traced through the harness and cant find any broken wires or bad connections

from what we have gathered so far the pgm fi unit is not sending any power to the fuel pump relay to power everything up.

if we put power direct to the ignition switch plug then everything works but wth the key in the off position.

does this sound like a faulty pgm fi unit?

 

What year?

 

is a 2012 foreman fm

 

Honda only made that model for a couple of years, so we don't get many to fix. If the lights, etc, work with ign switch on, there is power going through it to those items. However "for old times sake" Honda continue to use the 4 wire switch unit (double contacts) from earlier models. On some EFI models all one circuit does is power a relay which switches the power from the other half of the switch on and off, an entirely pointless exercise as far as I can tell. Anyway, I would guess that either the switch is faulty, or one circuit from the switch is faulty. Without the diagram I can't say what that is. The kill switch can cause those symptoms too, be sure it isn't that.

 

 

sent the wiring diagram, once running by bypassing the ignition switch, the kill switch on left handlebar works fine, so guessing that is ok
i have traced all the wires cant find any damaged wires

 

Struggling a bit with the wiring diagrams, but it looks like Main1 fuse feeds the Red/black, which joins the red, both go into ign switch and one feeds the black t'other pink. Pink goes to lights and accessories fuses but black feeds ign fuse and this feeds black/reds which power all sorts of things. I would try jumping a wire direct from pos battery terminal to black red spade in fuse box. This should cut out the ign switch and everything should work. If it doesn't, try jumping the pos terminal direct to the red/blacks in that massive junction box 2. I have a vague feeling I had the same fault and it was corrosion in that junction2 box. Think it was down the side of the fuel tank.

 

there is power at the ignition switch plug at black/red wire
nothing else is live here
that powers up the lights
i have tried putting power direct to the fuse box and that powers up everything
there is a starter relay that needs a signal from the ecu, this doesnt seem to be working, if the starter relay terminals are bridged then same again everything works.
there are two junction boxes beside the battery, not sure what they do, there is nothing beside the fuel tank on this bike.
there are loads of red black wires am i correct in saying they should all be live?

 

When you write "i have tried putting power direct to the fuse box and that powers up everything" where did you connect to in the box? If it is the ign fuse, then the black which feeds it from the ign switch must be dead, so trace back, is there power at the ign switch on the black (ign on)? If so the black has a break in it between switch and fuse box. If it isn't live at the switch, are the wires feeding the switch (red and red/black) both live? If they are, faulty switch. If they aren't, one must have a break in it, join them together (they are anyway, further back in the loom,) and everything will work.
Noticed there is an exception to my "they are anyway" statement about red and red/black being connected, normal bikes are but the "Canada only" drawing shows them being fed through complex relays before connecting.

 

Red black has power at the plug for the on off key switch.
Red has no power
Tried joining them at the plug and the ignition comes on with the key in the off position?
will try joining them further back in the loom see what happens.
I am in the u.k. so it is a canada spec bike that i have.
think the relays are trigged by the ecu