clutch sensor is at the clutch perch (on the handlebar,) on the underside has the little switch pull it off and crimp the wires together.

the kickstand sensor is at the kickstand mount, it's a very obvious plunger looking thing with a wire coming out of it...also crimp the two wires together.

 

In your case, the clutch and sidestand switches would not be your problem, they prevent the bike from even cranking. Aside from that, I have no other information. Maybe wiring to the coil? Maybe its just bad plugs? That would be where I would start looking but I dont know too much about electrical.

 

In your case, the clutch and sidestand switches would not be your problem, they prevent the bike from even cranking.

1+ Do you use a key or did you bridge the lock?
If so you need a to solder in a resistor.

 

If you moved wires around and zip tied them then you most likely either diconnected something by accident or had a bad wire that by moving it broke it's continuity. It isn't your switches since it wouldn't crank if they were bad. If you are not getting spark to both cylanders then it probably isn't coil wire either but I suspect that you may have diconnected a coil wire. That is very easy to do. Also, check the connections for the ECU module. They may be corroded enough to cause this. Logically you need the coils and the ecu to produce a spark. If it cranks then you don't have a ground issue.

 

Hey guys, thanks for the replies.

My bike already had the clutch/sidestand switch bypassed when I got it. The reason I asked about that was because I was led to believe you had to bypass several wires to do so, yet my connection for the sidestand was only unplugged (not resoldered with new connections) and the bike started last week. In addition, my ignition has been bypassed. I have the killswitch on the bar, however a toggle replaces the key and the pushbutton has been moved to the top clamp as well.

Image #1

 

Never understood bypassing the kickstand switch but what do I know?
So the bike was running after you replace the key lock with a toggle?
I for sure would like to see more pics of the bike because that is one of my favorite color schemes, do you have the colour codes?

 

do you have the colour codes

Unfortunatly no, I don't. I havn't changed anything on the bike...everything is the exact way I received it except that I stripped the subframe down to clean up the rear end, cleaned off everything else, de-varnished the carbs and neatened up all the tangles of tubes and wires with zipties. When it runs, it moves.....Getting to the whole "running" part though...thats the tricky area.

Halfway into the rebuild:

Before the rebuild: Looks the same, albeit a bit cleaner

My other ride, the 03 Kawi 636. Paint code on THAT is Dupont YS107

 

*Please read entire post, skimming will make following the ideas difficult*


Background information:
No tipover switch
No clutch position sensor
No kickstand
Keyed ignition removed/replaced by toggle/starter button + barmounted OEM killswitch

Alright guys Ive had more time to figure this out and trace wires on the bike. My wiring harness has been slightly modified...I've referenced the manual however Im having difficulty understanding some of the material. Ill start from the top.

From my neg. batt. term., a clipped extension runs to a 4-way wire intersection. These are the grounds. Ground A runs to the starter relay. Ground B runs to the regulator/rectifier. Ground C displays signs of solder, and hangs free in space. Ground C is "POINT #1".

According to the Ignition diagram presented below, the Ignition box must be grounded, which brings me to "POINT #1": Could this dangling ground be to the Ignition box?

Digital Ignition diagram:

If this ground is indeed to the ignition box, where would it plug into? From my digital ignition box I have an Orange/red lead and a Black/white lead. these two wires are cut and soldiered together with an in-line resistor. What leads me to believe that the ground went to these wires despite their colorings is the small-gauge heat-shrink tubing that the black dangling ground (ground C) fits perfectly into.

Also from the digital ignition is a Red/yellow wire and a Breen/black wire. These two have been cut down to ~4" and soldiered together "POINT #2": What are these two wires coming from the digital igniton?


"POINT #3": As displayed in my earlier post, "Image #1" displays the connector from my neutral sensing switch which should go to the sidestand. The manual says nothing about the red wire that I could find. How do I bridge this to isolate/remove the sidestand so the bike will start without the sidestand?

Lastly, from my regulator/rectifier to my starter relay is a Black/white wire. This wire is split between the regulator/rectifier and the starter relay, and the lead from the split runs to a small box measuring roughly 1cm x 11.5cm x 3cm long. On the top of this clear/whiteish box is a black plug-in unit. On the top of this small black unit is a symbol, blown up on the image below.

#POINT #4": What is this symbol? From the small whiteish box runs a Yellow/Green lead, that joins back with a similar lead from the starter relay and continues to the front of the motorcycle. What is this system of wires?


R/R-Starter relay diagram:

Thanks guys, hope my posts are explicit/detailed enough.

-Matt