Motorcycle Repair: cb 550 starter relay, honda cb 550, starter solenoid

Question
I have a 83 honda cb 550 nighthawk just bought.  It has a brand new two post four prong plug in starter relay from dennis kirk.  The bike has power and it runs bought it dose not start with the starter switch.  The starter works and the light gose out when you hit the switch but nothing happens.  Two of the four prongs have power red wire witch gose two the bike.  When you hit the switch the other two yellow power wires send power back two the relay.  I was wondering what makes the relay connect the + battery cable on the relay too the starter wire.  Wireing diagram would be help full or anything you can tell me.  My email is david.wellnitz@fabcon-usa.com  Thank you verry much

Answer
Hi David,

The starting system consists of the starter motor and clutch, the solenoid, and the handlebar mounted starter switch. When the button is pressed, the electrical circuit to the solenoid is closed and the solenoid is activated, sending the battery current directly to the starter motor. The starting system is quite reliable and it is unlikely that any major problems will arise.

Testing
  1. If the starter motor spins when the button is pushed, but the engine does not, the starter clutch is defective.
  2. If the warning lights dim when the starter button is pushed, but the engine and starter do not turn over, the battery may be too low, or the starter may be defective.
  3. If nothing happens when the starter button is pushed, either the starter solenoid is defective, or there is a loose wire in the electric starter circuit.
  4. If a "click" is heard when the starter button is pushed, but nothing else happens,
either the battery is too low to operate the starter motor, or there is a bad connection in the high tension cables from the battery to the solenoid or from the solenoid to the motor.
  5. Bad connections are the most likely source of trouble. If one is suspected, disconnect the starter motor cable from the battery and from the solenoid.
CAUTION: Disconnect the battery side first.
  6. Clean the copper eyelets with sandpaper until they are shiny. Before this cable is refitted, do the same to the cable from the solenoid to the starter motor.


More Starter Solenoid Testing

  1. If the battery is in reasonably good condition, and nothing at all happens when the starter button is pushed, check the solenoid.
  2. Disconnect the starter cable at the starter motor. When the button is pushed, there should be an audible "click" which indicates that the solenoid is opening.
  3. If further testing is necessary, remove the solenoid from the machine.
  CAUTION: Be sure to disconnect the cables at the battery before disconnecting the solenoid terminals.
  Connect a fully charged 12volt battery across the solenoid low tension leads and check for continuity across the hightension terminals with an ohmmeter or selfcontained test light. if there is no continuity, replace or repair the solenoid.
  4. Check for continuity across the low tension terminals with an ohmmeter or self powered test light. If there is none, the primary winding of the solenoid is broken, and the unit must be replaced.
  5. The primary cause of solenoid malfunction is pitting and/or burning of the contact points inside. It may be possible to restore a solenoid to serviceable condition by taking it apart and dressing the points with.a file or emery paper. If this doesn't work, replace it. Email me for directions on how to do this repair. Send me your email address as requested. I'll return the tech file.


Respectfully,
Mark Shively