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Discussion Starter #1
I replaced my clutch and during reassembly I seem to be having issues figuring out the starter wiring or I am having issues with the security system or a kill switch as I can not make it turn over. If you have information on this please contact me here or at 440-463-4822. Thanks
 

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Wrencher Extraordinaire
2005 K1200LT
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Not unusual. There is a black wire that leaves the starter in the middle that goes back to a tie point behind the battery (insulated cover). Usually the problem is in the number of wires re-attached to the positive terminal of the battery. Ther are several large red ones and one small one plus a black/yellow with a red sleeve.

Second biggest fault is if you removed the switches on the reverse lever. They are prone to breakage and one of the functions is to route the starter signal from the starter relay to the reverser controller. I'll give you a call tonight when I get off work.
 

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Registered seven years ago and this is his first post? Talk about a lurker! ;)

Had a similar no-go issue when I changed my clutch last month. Will leave it to JZ as he is has an amazing amount of LT expertise. You are in good hands.

Please post what needed up being your issue, and please also fill out your profile.
 

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Discussion Starter #4
You are right about the lurking part. My first experience with this board was when I found the Tupperware Party post about a year after I bought the bike. That was a huge help getting the tupperware off the first time and I was hooked on this forum forever. This forum has been a huge help. I really did not post before because pretty much every problem I have ever had has either already been discusses thoroughly or was under warranty. I also want to thank you, David, and John for stepping up to help. John also called and I will call him back this afternoon to discuss a few other minor questions I still have.

Friday, I talked to David Shealey and he also provide information on the black wire adn the reverse switch. I was pretty sure when I saw what I had done, which was connect the brown ground wire to the starter where the black power wire should have connected to the starter (and when I connected it I did not even see the black wire hanging there) and I was fat, dumb, and happy until I had it all back together and it would not start. Then looking around I found the errant black wire and knew I had connected the wrong wire to the starter. However, that is where the mystery started. I connected the black properly but I still could not get it to start and assumed that it was because the ground wire needed to be connected but I could not figure out where to attach it. After talking to Dave I tried to connect the ground wire to the top alternator bolt but the bolt was too big to go through the connector. Finally, even thought I was pretty sure it did not come off the starter I attached it to the bolt at the back of the starter. When I did that and hit the starter switch it fired right up. So, I assumed that was the problem and installed the cross member, swing arm, and final drive. I also reinstalled the reverse switch mounting hardware and was getting ready to install the exhaust. At that point I decided to try to start it again and guess what. It would not turn over and the relay would not even click. So, based on David's advice I looked into the reverse aid switch and by playing with it I could get it to start but every time I installed the hardware it would not start. Eventually, the last time I took it off a small plunger from one of the switched fell out which lead me to belive it was bad all along and I ordered a new one. Bottom line, I had two problems and was lucky that when I installed the ground wire the reverse switch decided to cooperate enough to let it start which at least told me it was not a starter problem and I was then able to focus on other possible issues.

So, now my questions are:

Where should that brown ground wire really be attached and will it hurt anything to leave it where it is?

When I reinstall the reverse aid switch are there any nuances that will help keep me from damaging it again?

Thanks! Jim
 

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2005 K1200LT
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The ground goes on the stud behind the starter on top of the tranny and to the crossmember.
 

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Discussion Starter #6
Thanks. I am pretty sure that is where I finally wound up putting it. Because the starter mounts to the transmission housing right below it I called it a stud on the back of the starter. Will the system run properly without it being installed? I ask because a) it looks like a double ground which would be redundant and b) because I don;t remember taking it off and when I went to attach it the nut on the stud was very tight like it had not been removed. I am wondering if the dealer left it off when they did the last clutch under warranty at 6,800 miles. Thanks again for your help!

Jim
 

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Discussion Starter #7
BTW, where did you get that picture I looked everywhere for anything to show me where that might go. Jim
 

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When installing the reverse switch, you have to be sure to get the little actuating "pins" over the shaft properly, or one can be sheared off. If I remember correctly (I had the same problem once) you can align them with the flat on the shaft when pushing the switch assembly back over the shaft.
 

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2005 K1200LT
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jadoglio said:
BTW, where did you get that picture I looked everywhere for anything to show me where that might go. Jim
Like I said in our phone call, those images are in the old BMW LT manual in the "General Electrical" section. I use all three manuals for what they have to offer. Old PDF LT, new interactive DVD LT and the Clymers.
 

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Discussion Starter #10
David and John

Thanks again for your help! David, I think that is exactly what happened to the switch. I have ordered a new switch and it should be in on Friday. You can bet I will be a bit more careful when I put in back together this time. I would have never thought for a minute that BMW would use such a fragile design on this part.

One last question, Is it also possible to overtighten the mounting bolt and caussing damage that way? It seems that the collar on the rocker that goes through the center of the switch would keep that from happening but I think I may have overtightened it as well.

I owe you both, if you are ever in the Cleveland area let me know!

Jim
 

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Discussion Starter #11
Last update. Got the new reverse aid switch and installed it last night. All was well with this installation. It worked as designed. Thought I was done. Backed the bike off of the lift started it hit first gear and it died immediately. Figured it was the side stand switch. Back ont he lift. Removed the shift lever (again) and checked the switch. Called John Z. to discuss and we concluded that it pretty much had to be the switch. Got out the DVM tested the switch and it was showing that there was an issue with it. However, the connectors are very small and hard to test. Eventually we jumped the sidestand switch white and brown wires and John did a little investigating on his LT to see if my switch was operating normally as the wiper would turn 360 degrees and we were not sure if it was supposed to do that or not. At the end of the experimenters, the jumper allowed the bike to start and continue to run in gear which pretty much confirmed the switch was bad.

Went to e-Bay found a used switch for $30 and ordered it. Tonight I was preparing the old switch for removal and when I removed the wire ties off of the kick stand and pulled the wire loose I found we had pinched it when we reinstalled the center stand and cut through the white wire on the switch. I repaired the wire removed the jumper and tested the swith with the DVM again and it was working fine. I put the shifter back on backed it off of the lift started it up and drove it about 3 miles to test it. Everything seem sot be working as designed.

I am still going to install the new switch as it will not have the spliced wire in it. If anyone needs the old switch for anything let me know.

Thanks agian to John and David for their help and support.
 
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