SkunkWorks
Well-Known Member
Almost exactly a year ago, during my Arizona Trip with my friend Cap'n Ron, there was an instance where I had parked at the side of the road for a brief period of time.
When I went to restart the bike it was in-gear with the clutch pulled in, side-stand was not down.
Nothing happened...................No Crank, No Click.........Nothing, except "19" was displayed on the right-hand screen.
At the time I clicked the gearbox into neutral, cycled the key off and then back on, and then it started like normal.
I recorded the Fault-Code 19 and we went on our way................It did not happen again the rest of that trip, or again for quite some time.
After I got home from that trip I looked up the Fault-Code and found the "Side-Stand Switch" designation. I had sort-of dismissed it as it did not happen again, or since.
Fast forward to earlier this season when the same thing would happen at random times while I was out on a ride. Always after I had parked the bike for a brief period of time and left the key on, while taking a picture or checking my route, etc.......... It would not crank while in-gear with the clutch pulled in, after putting the side-stand up. I would have to click it into neutral, and it would always start normally.
The only time it ever showed the "Fault-Code 19" on the Display was the very first time, while I was in Arizona. Any other time it happened it did not display the code.
This summer the instances became more frequent...........Enough so that I began to pay attention to every time I parked the bike, and then tried to start it in-gear.
It did not happen every single time, and was definitely random, but was happening more often for sure.
I went on another week-long tour of the Desert-Southwest a few weeks ago, and by this time it was happening a lot.
It became annoying and inconvenient.
After this Trip I did the research on the "NoCrank" symptoms, and the Code-19 Fault.
I came up with all sorts of things that could cause this. The most common were:
Ignition Switch is faulty.
Side-Stand Switch is faulty.
Clutch Switch is faulty.
Neutral Switch is faulty.
Wiring for any one of these is faulty or compromised.
I started with the easiest to access and most obvious thing first. The Side-Stand Switch.
Initial inspection looked good. Plunger moves as it should. Doesn't stick and moves smoothly.
Side-Stand activates it and deactivates it when operated.
I originally was going to do a resistance test at the connector, but to get to that harness junction I will have to lift the fuel-tank to access it. It's too far up in the frame to reach my hands in there.
So I set about removing the Switch from its mount, and disassembling it. It is really easy to access.
There are just the two Nuts on the back that use an 8mm wrench, and the allen-head screws,
These 4 JIS screws and it comes right apart.
It was actually pretty clean inside.
No evidence of any water or dirt intrusion into the Switch, even given that I've taken the bike through many water-crossings recently.
The Switch is sealed with a rubber gasket, and a seal around the plunger shaft. Mine is in really good shape.
The grease that lubes the plunger movement looked clean, and it appeared there was enough of it in there, so I did not add any more.
The Switch works by either connecting the two copper buttons or disconnecting them when the plunger moves in and out. The two harness wires are directly attached to these buttons.
A spring with a decent amount of compression-force keeps the plunger pushed all the way out when the side-stand is not contacting it to push it in.
When the plunger is pushed all the way out by the spring, the buttons are connected by a copper-bar that is held against them by a second smaller spring.
The copper Buttons and the copper Bar inside my Switch had a slight "film" of darker colored (oxidation) on them.
It really didn't look that bad, but was noticeable.
I cleaned them all with a small piece of Scotchbrite pad.
When I reassembled the Switch, I stretched this tiny spring very slightly to put just a slight amount of additional tension on the copper-bar.
My thought was that it should hold just a bit more contact force making the electrical connection between the two buttons as it operates.
After bolting the Switch back on the bike and testing it, everything appeared to work as it should.
I have since ridden the bike to work and back for a week, as well as short rides on my lunch-break. Even an all-day ride with the guys this past Saturday.
The bike has started every single time since, while trying to start it in-gear with the clutch pulled-in.
Have not had even one random instance where it would not crank.
Will monitor it going forward to make sure that this was indeed the cause of the issue. For now it looks like it was.
If it does happen again in the future, I will dig deeper into the diagnostic process and post an update to this thread.
When I went to restart the bike it was in-gear with the clutch pulled in, side-stand was not down.
Nothing happened...................No Crank, No Click.........Nothing, except "19" was displayed on the right-hand screen.
At the time I clicked the gearbox into neutral, cycled the key off and then back on, and then it started like normal.
I recorded the Fault-Code 19 and we went on our way................It did not happen again the rest of that trip, or again for quite some time.
After I got home from that trip I looked up the Fault-Code and found the "Side-Stand Switch" designation. I had sort-of dismissed it as it did not happen again, or since.
Fast forward to earlier this season when the same thing would happen at random times while I was out on a ride. Always after I had parked the bike for a brief period of time and left the key on, while taking a picture or checking my route, etc.......... It would not crank while in-gear with the clutch pulled in, after putting the side-stand up. I would have to click it into neutral, and it would always start normally.
The only time it ever showed the "Fault-Code 19" on the Display was the very first time, while I was in Arizona. Any other time it happened it did not display the code.
This summer the instances became more frequent...........Enough so that I began to pay attention to every time I parked the bike, and then tried to start it in-gear.
It did not happen every single time, and was definitely random, but was happening more often for sure.
I went on another week-long tour of the Desert-Southwest a few weeks ago, and by this time it was happening a lot.
It became annoying and inconvenient.
After this Trip I did the research on the "NoCrank" symptoms, and the Code-19 Fault.
I came up with all sorts of things that could cause this. The most common were:
Ignition Switch is faulty.
Side-Stand Switch is faulty.
Clutch Switch is faulty.
Neutral Switch is faulty.
Wiring for any one of these is faulty or compromised.
I started with the easiest to access and most obvious thing first. The Side-Stand Switch.
Initial inspection looked good. Plunger moves as it should. Doesn't stick and moves smoothly.
Side-Stand activates it and deactivates it when operated.
I originally was going to do a resistance test at the connector, but to get to that harness junction I will have to lift the fuel-tank to access it. It's too far up in the frame to reach my hands in there.
So I set about removing the Switch from its mount, and disassembling it. It is really easy to access.
There are just the two Nuts on the back that use an 8mm wrench, and the allen-head screws,
These 4 JIS screws and it comes right apart.
It was actually pretty clean inside.
No evidence of any water or dirt intrusion into the Switch, even given that I've taken the bike through many water-crossings recently.
The Switch is sealed with a rubber gasket, and a seal around the plunger shaft. Mine is in really good shape.
The grease that lubes the plunger movement looked clean, and it appeared there was enough of it in there, so I did not add any more.
The Switch works by either connecting the two copper buttons or disconnecting them when the plunger moves in and out. The two harness wires are directly attached to these buttons.
A spring with a decent amount of compression-force keeps the plunger pushed all the way out when the side-stand is not contacting it to push it in.
When the plunger is pushed all the way out by the spring, the buttons are connected by a copper-bar that is held against them by a second smaller spring.
The copper Buttons and the copper Bar inside my Switch had a slight "film" of darker colored (oxidation) on them.
It really didn't look that bad, but was noticeable.
I cleaned them all with a small piece of Scotchbrite pad.
When I reassembled the Switch, I stretched this tiny spring very slightly to put just a slight amount of additional tension on the copper-bar.
My thought was that it should hold just a bit more contact force making the electrical connection between the two buttons as it operates.
After bolting the Switch back on the bike and testing it, everything appeared to work as it should.
I have since ridden the bike to work and back for a week, as well as short rides on my lunch-break. Even an all-day ride with the guys this past Saturday.
The bike has started every single time since, while trying to start it in-gear with the clutch pulled-in.
Have not had even one random instance where it would not crank.
Will monitor it going forward to make sure that this was indeed the cause of the issue. For now it looks like it was.
If it does happen again in the future, I will dig deeper into the diagnostic process and post an update to this thread.
