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2003 Road Star 1600_Engine dies when shifted into gear

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  • 2003 Road Star 1600_Engine dies when shifted into gear

    2003 RS, No fuel pump,
    Runs perfect out of gear,
    Clutch in, shift into gear, engines dies.

    Stand switch checked good - contacts cleaned and reassembled.
    Clutch lever switch bypassed - looked like crap inside.
    Bike runs perfect.
    Rolls in gear clutch in or in neutral.
    Clutch plates don't appear to be locked up.
    Neutral light working properly.
    Relay not swapped yet.
    Kill switch working properly.
    Diode not yet checked.

    Something is telling the Ignition Module to kill the motor?
    Clutch in - Dies when shifted - no lurch or drag down of RPM - just dies like you hit the kill switch.

    Factory Manual little to no help.
    Form topics say check clutch and kick stand switches - done that or bypassed.

    Dazed and confused...

    I do get it that the clutch and kickstand switches control the start relay circuit.

    Any help most appreciated.



  • #2
    .

    Comment


    • #3
      Try bypassing the kick stand switch to take it out of the loop.

      Comment


      • #4
        Ya, gotta be something to do with that kickstand switch.
        It's not that life is so short, it's just that you're dead for so long.---unknown.

        Comment


        • #5
          Agreed on the kickstand switch. Good friend of mine has the exact same thing going on right now. Same year I think too actually.

          Comment


          • #6
            I will be on it again tomorrow. Had to go out of state today. New Clutch switch in route/

            Comment


            • Bikerron
              Bikerron commented
              Editing a comment

              I do get it that the clutch and kickstand switches control the start relay circuit.




              Clutch switch won’t let the starter engage if it’s in gear unless you pull it, but it doesn’t control the ignition spark.

              The side stand down will allow spark to run the engine only if in neutral. As soon as you put it in gear, both paths to the coils are interrupted and it’ll kill the engine.

              I’d be checking the wiring to the side stand switch if you think it’s working. A multimeter is the only way to check continuity through the switch.

            • jimships
              jimships commented
              Editing a comment
              Clutch Switch replaced. It was sort of bad, switch was not snappy, but not the trouble. New SCCR in route. I have checked into this a lot and even started making a schematic of the SCCR to be able to diagnose the issue. I found a diagram and believe it is close if not correct for the SCCR functionality. I will add it to the end of the thread since this (in comment text box) does not allow it. Thanks for all the help...and for those wondering, no I am still not running...(argh) but coming back to it after taking a long break for work and family.

          • #7
            My 03 RS has done that probably 3 or 4 times within the last 5 years. Never looked into it and the bike would always re start. Something to check now thanks for the info!
            "It's not the destination...it's the ride"

            Comment


            • #8
              This image came from another post in a different forum. The logic of the relays look right though and the explanation written seems sound.

              Comment


              • #9
                The diode relay (#7) is next inline for suspicious activity.

                And, even #9 would stir my curiosity.

                seriously, I’d consider getting a factory service manual for it if you have a multimeter and can follow some directions on how to test everything listed. It’s in the book.

                https://www.ebay.com/itm/254962353940

                Comment

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