Understanding/troubleshooting the safety switches: Difference between revisions

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This article explains how the various safety switches on the EX250 work together and also gives some tips for figuring out if you have a problem with one or more of them.

This article explains how the various safety switches on the EX250 work together and also gives some tips for figuring out if you have a problem with one or more of them. Please see the [[Electrical & Lighting]] section of the FAQ for other articles on the switches.

This is somewhat EX250-specific. Other bikes may have a different combination of switches and may work differently. Check ''their'' FAQ.

==The components and how they work==

*The clutch lever safety switch is a single pole, double throw (SPDT) switch located on the left-side handlebar at the clutch lever. When the clutch lever is in the released (clutch engaged) position the safety switch is connected to the gear selector safety switch. When the clutch lever is in the pulled-in (clutch disengaged) position the safety switch is connected to chassis ground.

*The clutch lever safety switch is a single pole, double throw (SPDT) switch located on the left-side handlebar at the clutch lever. When the clutch lever is in the released (clutch engaged) position, the safety switch is connected to the gear selector safety switch. When the clutch lever is in the pulled-in (clutch disengaged) position, the safety switch is connected to chassis ground.

*The gear selector safety is a single pole, single throw (SPST) switch located behind the drive sprocket cover on the left side of the motorcycle. When the transmission is in neutral the safety switch closes and completes a circuit to chassis ground (neutral lamp on dash is illuminated). When the transmission is out of neutral (in gear) the safety switch opens and the circuit is not completed.

*The gear selector safety is a single pole, single throw (SPST) switch located behind the drive sprocket cover on the left side of the motorcycle. When the transmission is in neutral, the safety switch closes and completes a circuit to chassis ground (neutral lamp on dash is illuminated). When the transmission is out of neutral (in gear) the safety switch opens and the circuit is not completed.

*The sidestand safety is a single pole, single throw (SPST) switch located at the sidestand pivot bracket on the left side of the motorcycle. When the sidestand is in the up (riding) position the safety switch closes and completes a circuit to chassis ground. When the sidestand is down (parked) the safety switch opens and the circuit is not completed.

*The sidestand safety is a single pole, single throw (SPST) switch located at the sidestand pivot bracket on the left side of the motorcycle. When the sidestand is in the up (riding) position, the safety switch closes and completes a circuit to chassis ground. When the sidestand is down (parked) the safety switch opens and the circuit is not completed.

*The starter circuit relay is a single pole, single throw (SPST) relay located in the junction box behind the right side panel. The starter circuit relay is a component of the starter solenoid coil circuit that allows current to pass to the starter solenoid coil when certain safety switch conditions are met.

*The ignition module is located behind the left side panel. The ignition module is responsible for creating the spark at the spark plugs in a timely manner. The ignition module is a component of the safety switch circuits, and will not operate unless certain safety switch conditions are met.

==The start circuit==

For more assistance, see [[Start & Ignition Schematic.pdf]]

For more assistance, see [[Wiring schematics & diagrams|Start & Ignition Schematic.pdf]]

'''Short version'''

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However, success is short-lived, as the motorcycle cannot be driven at this time. Up to this point the ignition module connection to ground has been provided by a combination of the clutch lever safety switch position and the gear selector safety switch position.

The problem arises as the clutch lever is pulled in (clutch lever safety switch changes position - connects to ground), the transmission is shifted out of neutral and into gear (gear selector safety switch opens - no connection to ground), and the clutch lever is slowly released (the clutch lever safety switch changes position - connects to the gear selector safety switch), disconnecting the ground connection to the ignition module enable circuit, and stopping the engine.

The problem arises as the clutch lever is pulled in (clutch lever safety switch changes position - connects to ground), the transmission is shifted out of neutral and into gear (gear selector safety switch opens - no connection to ground), and the clutch lever is slowly released (the clutch lever safety switch changes position - connects to the gear selector safety switch), disconnecting the ground connection to the ignition module enable circuit and stopping the engine.

This is where the sidestand comes into play; with the sidestand in the down (parked) position, the sidestand safety switch is open (no connection to ground). When the sidestand is raised to the up (riding) position, the sidestand safety switch closes (connecting to ground) and completes the ignition module enable circuit, allowing the motorcycle to be driven. As the sidestand safety switch is only a component of the run circuit, and not a component of the start circuit, the position of the sidestand is not relevant when diagnosing starting problems.

This is where the sidestand comes into play; with the sidestand in the down (parked) position, the sidestand safety switch is open (no connection to ground). When the sidestand is raised to the up (riding) position, the sidestand safety switch closes (connecting to ground) and completes the ignition module enable circuit, allowing the motorcycle to be driven. As the sidestand safety switch is only a component of the run circuit, and not a component of the start circuit, '''the position of the sidestand is not relevant when diagnosing ''starting'' problems'''.

====Safety Switch Facts====

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==Troubleshooting the safety switches==

For more help, see [[Start & Ignition Troubleshoot Schematic.pdf]]

For more help, see [[Wiring schematics & diagrams|Start & Ignition Troubleshoot Schematic.pdf]]

====Starting Problem====

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With the Green/White and Black/Yellow wires temporarily connected, the sidestand safety switch has been bypassed, and the ground to the ignition module enable circuit has been restored. If the motorcycle runs, then most likely the sidestand safety switch is faulty. If the motorcycle still does not run, then the fault is elsewhere. Remember to reconnect the sidestand safety switch to the wire harness when finished trouble-shooting. Failing to do so is '''very unsafe'''.

Before deciding to replace a safety switch, a quick inspection may turn up a misaligned switch plunger, or a buildup of road grime around the switch, preventing the switch plunger from fully extending. Frequently all that is needed is a good cleaning and a spritz of WD-40 for lubrication. Tempting as it may be to operate the motorcycle with the safety switches bypassed, DON'T. The safety switches perform two very important safety ~~features~~:

Before deciding to replace a safety switch, a quick inspection may turn up a misaligned switch plunger, or a buildup of road grime around the switch, preventing the switch plunger from fully extending. Frequently all that is needed is a good cleaning and a spritz of WD-40 for lubrication. Tempting as it may be to operate the motorcycle with the safety switches bypassed, DON'T. The safety switches perform two very important safety functions:

1.The motorcycle cannot be started when the transmission is in gear and the clutch is released. This is especially important if you are in the habit of parking the motorcycle using the sidestand, and starting the motorcycle while not straddling it. Watching your Ninja jump forward and fall to the ground due to being in gear when it was started is no fun.

:1. The motorcycle cannot be started when the transmission is in gear and the clutch is released. This is especially important if you are in the habit of parking the motorcycle using the sidestand and starting the motorcycle while not straddling it. Watching your Ninja jump forward and fall to the ground due to being in gear when it was started is no fun.

2.The motorcycle cannot be driven with the sidestand down in the parked position. Driving with the sidestand down can be dangerous, and easy to do.

:2. The motorcycle cannot be driven with the sidestand down in the parked position. Driving with the sidestand down can be dangerous, and is all-too-easy to do.

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-This article explains how the various safety switches on the EX250 work together and also gives some tips for figuring out if you have a problem with one or more of them.
+This article explains how the various safety switches on the EX250 work together and also gives some tips for figuring out if you have a problem with one or more of them. Please see the [[Electrical & Lighting]] section of the FAQ for other articles on the switches.
+This is somewhat EX250-specific. Other bikes may have a different combination of switches and may work differently. Check ''their'' FAQ.
 ==The components and how they work==
-*The clutch lever safety switch is a single pole, double throw (SPDT) switch located on the left-side handlebar at the clutch lever.  When the clutch lever is in the released (clutch engaged) position the safety switch is connected to the gear selector safety switch. When the clutch lever is in the pulled-in (clutch disengaged) position the safety switch is connected to chassis ground.
+*The clutch lever safety switch is a single pole, double throw (SPDT) switch located on the left-side handlebar at the clutch lever.  When the clutch lever is in the released (clutch engaged) position, the safety switch is connected to the gear selector safety switch. When the clutch lever is in the pulled-in (clutch disengaged) position, the safety switch is connected to chassis ground.
-*The gear selector safety is a single pole, single throw (SPST) switch located behind the drive sprocket cover on the left side of the motorcycle.  When the transmission is in neutral the safety switch closes and completes a circuit to chassis ground (neutral lamp on dash is illuminated).  When the transmission is out of neutral (in gear) the safety switch opens and the circuit is not completed.
+*The gear selector safety is a single pole, single throw (SPST) switch located behind the drive sprocket cover on the left side of the motorcycle.  When the transmission is in neutral, the safety switch closes and completes a circuit to chassis ground (neutral lamp on dash is illuminated).  When the transmission is out of neutral (in gear) the safety switch opens and the circuit is not completed.
-*The sidestand safety is a single pole, single throw (SPST) switch located at the sidestand pivot bracket on the left side of the motorcycle.  When the sidestand is in the up (riding) position the safety switch closes and completes a circuit to chassis ground.  When the sidestand is down (parked) the safety switch opens and the circuit is not completed.
+*The sidestand safety is a single pole, single throw (SPST) switch located at the sidestand pivot bracket on the left side of the motorcycle.  When the sidestand is in the up (riding) position, the safety switch closes and completes a circuit to chassis ground.  When the sidestand is down (parked) the safety switch opens and the circuit is not completed.
 *The starter circuit relay is a single pole, single throw (SPST) relay located in the junction box behind the right side panel.  The starter circuit relay is a component of the starter solenoid coil circuit that allows current to pass to the starter solenoid coil when certain safety switch conditions are met.
 *The ignition module is located behind the left side panel.  The ignition module is responsible for creating the spark at the spark plugs in a timely manner.  The ignition module is a component of the safety switch circuits, and will not operate unless certain safety switch conditions are met.
 ==The start circuit==
-For more assistance, see [[Start & Ignition Schematic.pdf]]
+For more assistance, see [[Wiring schematics & diagrams|Start & Ignition Schematic.pdf]]
 '''Short version'''
@@ Line 46: / Line 48: @@
 However, success is short-lived, as the motorcycle cannot be driven at this time.  Up to this point the ignition module connection to ground has been provided by a combination of the clutch lever safety switch position and the gear selector safety switch position.
-The problem arises as the clutch lever is pulled in (clutch lever safety switch changes position - connects to ground), the transmission is shifted out of neutral and into gear (gear selector safety switch opens - no connection to ground), and the clutch lever is slowly released (the clutch lever safety switch changes position - connects to the gear selector safety switch), disconnecting the ground connection to the ignition module enable circuit, and stopping the engine.
+The problem arises as the clutch lever is pulled in (clutch lever safety switch changes position - connects to ground), the transmission is shifted out of neutral and into gear (gear selector safety switch opens - no connection to ground), and the clutch lever is slowly released (the clutch lever safety switch changes position - connects to the gear selector safety switch), disconnecting the ground connection to the ignition module enable circuit and stopping the engine.
-This is where the sidestand comes into play; with the sidestand in the down (parked) position, the sidestand safety switch is open (no connection to ground). When the sidestand is raised to the up (riding) position, the sidestand safety switch closes (connecting to ground) and completes the ignition module enable circuit, allowing the motorcycle to be driven.  As the sidestand safety switch is only a component of the run circuit, and not a component of the start circuit, the position of the sidestand is not relevant when diagnosing starting problems.
+This is where the sidestand comes into play; with the sidestand in the down (parked) position, the sidestand safety switch is open (no connection to ground). When the sidestand is raised to the up (riding) position, the sidestand safety switch closes (connecting to ground) and completes the ignition module enable circuit, allowing the motorcycle to be driven.  As the sidestand safety switch is only a component of the run circuit, and not a component of the start circuit, '''the position of the sidestand is not relevant when diagnosing ''starting'' problems'''.
 ====Safety Switch Facts====
@@ Line 59: / Line 61: @@
 ==Troubleshooting the safety switches==
-For more help, see [[Start & Ignition Troubleshoot Schematic.pdf]]
+For more help, see [[Wiring schematics & diagrams|Start & Ignition Troubleshoot Schematic.pdf]]
 ====Starting Problem====
@@ Line 83: / Line 85: @@
 With the Green/White and Black/Yellow wires temporarily connected, the sidestand safety switch has been bypassed, and the ground to the ignition module enable circuit has been restored.  If the motorcycle runs, then most likely the sidestand safety switch is faulty.  If the motorcycle still does not run, then the fault is elsewhere.  Remember to reconnect the sidestand safety switch to the wire harness when finished trouble-shooting. Failing to do so is '''very unsafe'''.
-Before deciding to replace a safety switch, a quick inspection may turn up a misaligned switch plunger, or a buildup of road grime around the switch, preventing the switch plunger from fully extending.  Frequently all that is needed is a good cleaning and a spritz of WD-40 for lubrication.  Tempting as it may be to operate the motorcycle with the safety switches bypassed, DON'T.  The safety switches perform two very important safety features:
+Before deciding to replace a safety switch, a quick inspection may turn up a misaligned switch plunger, or a buildup of road grime around the switch, preventing the switch plunger from fully extending.  Frequently all that is needed is a good cleaning and a spritz of WD-40 for lubrication.  Tempting as it may be to operate the motorcycle with the safety switches bypassed, DON'T.  The safety switches perform two very important safety functions:
-.The motorcycle cannot be started when the transmission is in gear and the clutch is released. This is especially important if you are in the habit of parking the motorcycle using the sidestand, and starting the motorcycle while not straddling it.  Watching your Ninja jump forward and fall to the ground due to being in gear when it was started is no fun.
+:1. The motorcycle cannot be started when the transmission is in gear and the clutch is released. This is especially important if you are in the habit of parking the motorcycle using the sidestand and starting the motorcycle while not straddling it.  Watching your Ninja jump forward and fall to the ground due to being in gear when it was started is no fun.
-.The motorcycle cannot be driven with the sidestand down in the parked position.  Driving with the sidestand down can be dangerous, and easy to do.
+:2. The motorcycle cannot be driven with the sidestand down in the parked position.  Driving with the sidestand down can be dangerous, and is all-too-easy to do.