1400 always wants to start without pushing start button, kill switch on

[Mikeylikesit522]

Hey hey. So this is my first post. Buddy of mine gifted me a 1990 Intruder 1400. It was running last year when the guy riding it said that it started sparking and seemed like something was catching fire. My buddy loaded it up and brought it back home and it’s sat. Well he turned it over to me as a new project and here’s what I found.

- Battery terminal on negative side basically melted thru the post.
- key in, touch battery to what’s left of the post and no lights but it attempts to turn over (even in gear)
- hit the kill switch, same thing bike still attempts to turn over with the kill switch in the off position.
- cable sparks whenever touched to the negative battery terminal. Gets EXTREMELY hot.

Best I can figure is that maybe the starter is shorted and keeps trying to start whenever there’s power. If anyone has a wiring diagram for this bike I’d love to see it.
Not new to working on bikes, if I gotta swap out the wiring harness or chase a short I’ll do it. Just thought I’d try and get some pointers as to where to start.

Also any secrets to battery model/manufacturer that has the side post screw vs front/top terminal screws?

Thanks in advance. Looking forward to getting this bike up and running. It’ll be my first cruiser since I’ve been a crotch rocket guy for the last 18 years.

[Herb]

This is a new one on me. I have never seen a ground wire overheat from a short, it has always been the positive wire that overheats.

I would say that something on the start circuit shorted out and is causing the starter selenoid to stay engaged. Whatever is happening I would say that it is also shorted to ground.

[sgtcall]

Welcome!
Here are a couple of things to check out.

INTRUDER MANUALS AND INFORMATION
viewtopic.php?f=19&t=14168

POSTING PICTURES ON INTRUDERS ALERT
viewtopic.php?f=19&t=13992

[Herb]

SgtCall has provided links to manuals and wiring diagrams that should put you in the right direction.

Thinking about things, are you sure that the melted cable end is the negative (ground) cable?

[Mikeylikesit522]

Haha I hadn’t actually thought about that. It’s on the right hand side of the bike and looked like a negative wire but I suppose I could be wrong.

[Herb]

Is the battery in correctly?

[Mikeylikesit522]

Is the battery in correctly?

Yep. It is in correctly. Was in the way it was when it was running. Nothing has been touched since it was actively was being ridden for weeks/months up til the point where the terminal started sparking and melted the battery post.

I’ve ordered as starter and a starter solenoid as a starting point. I’ll replace the solenoid first, if same results I’ll replace the starter next. While waiting on those parts I’ve also ordered a new negative terminal cable as well and will go ahead and clean the contacts on the start button and the kill switch.

What’s perplexing to me is that it attempts to start even when in gear, kickstand down, and kill switch set to off (not in the run position)

[Herb]

The only way that can happen is if the power wire to the start solenoid has power on it or the solenoid is shorted internally.

Disconnect the trigger wire to the solenoid and if it still tries to start the solenoid is bad, if it doesn't there is an issue with the trigger wire and there has to be a short in the wiring to power up the solenoid.

[Mikeylikesit522]

Well looks like it is a bad solenoid.

Removed seat and side panel and was able to access the solenoid. Gave it a couple taps and while it still won’t fully turnover and start it no longer attempts to start as soon as the battery is connected. No more arcs/sparks thankfully.

New solenoid should be here towards the end of next week.

Adding the following notes in case someone searches this topic in the future.

Note: bad solenoid: no key, in gear, kill switch on, the bike would attempt to start but no lights would illuminate at all.

After tapping the solenoid: no activity with the battery connected. Turn the key lights come on now, the kill switch functions as it should. Start button engages the solenoid, lots of ticking and can hear the motor trying to turnover as it attempts to start but no luck in successfully starting the bike.

More to follow once I get a new starter solenoid installed and a new battery.

[navigator]

Motobatt makes the correct battery for your bike...side terminals.

[Mikeylikesit522]

Solenoid came in and picked up a new battery. Bike fired right up there’s a few little odds and ends that I gotta do but it’s basically good to go.

Next up:
Choke Cable inspection (choke adjustment has no effect currently)
Tank: pull/fill dents and paint.
Tires: ole girl needs some new shoes
Turn signals: rear signals don’t work. Probably a fuse
Batwing fairing - MAYBE

[hillsy v2]

Turn signals: rear signals don’t work. Probably a fuse

If the front signals light up it's not a fuse. More than likely the connector(s) for the rear are unplugged or they aren't grounded.