Engine cuts out when put in gear

[Dead Eye]

So I've finally got to a point in my rebuild, after the crash 4 weeks ago, that I was ready to test the bike on the road...

Bike was reluctant to start at first, but it came to life and everything seemed like normal. Still on the centre stand I figured I'd check everything out first to make sure I didn't get any nasty surprises. Kicked it in to gear with the clutch pulled in and the engine cuts out... crap.

So I put my investigating hat on and immediately set about checking the Sidestand switch. Got my multimeter out and checked resistance across the switch - all good! Checked the Fuses (Haynes suggested to ) and they all seem fine. At this point my multi-meter decided it would run out of battery power and I don't have any spares so that's me done for now and figured I'd get some ideas from you good folk

So here it is laid out;

• Engine cuts out when put in to gear
• Sidestand switch tested ok with multi-meter
• Fuses ok
• Engine off, in 1st, clutch pulled in - won't start

I'm thinking my next step is to test the clutch switch?

[ChristoT]

Is the side stand switch actually engaging / disengaging properly?

[Dead Eye]

Yes... I did say that I had tested it with a multi-meter...

[ChristoT]

Yes... I did say that I had tested it with a multi-meter...

That means the electric part is working, not necessarily the mechanical part. Just thought I'd chuck it out there.

Clutch switch is a possible culprit.

[Dead Eye]

That makes no sense - if the switch is working electronically then obviously the mechanical part is working. Aka, it shows the correct change in resistance as the switch is operated

[ChristoT]

it shows the correct change in resistance as the switch is operated

OK, sorry, the OP hadn't made that clear.

[Dead Eye]

So mentioning twice that I had tested the switch and it was ok wasn't making it clear... have you been to doctors after your crash?

[ChristoT]

So mentioning twice that I had tested the switch and it was ok wasn't making it clear... have you been to doctors after your crash?

Sod off. That is all.

When you said you'd tested the switch, I wasn't sure of WHAT exactly you had tested. Hence why I double checked.

You can thank me later for the bump, BTW. 

[mr self destruct]

So mentioning twice that I had tested the switch and it was ok wasn't making it clear... have you been to doctors after your crash?

I think Christo is asking if the sidestand actually operates the switch effectively, no matter how good the switch itself is. That part of it you haven't made clear.

[Dead Eye]

Ok.

I got down on my hands and knees to look a the side stand switch and mechanism. It was covered in crap so I gave it a good clean (this is AFTER the problem presented itself). I could see the mechanism operating correctly as a lowered and raised the side stand in order for the switch rod to retract and be pushed back in.

I then attached the multimeter to the end of the cable that feeds the side stand switch where it is connected behind the left hand panel. With the sidestand up there was no resistance, and with my foot I push the side stand down and the resistance became infinite.

This to me clarifies that the switch and mechanism is operating correctly

[mr self destruct]

Ok cool.


Is the clutch adjusted properly? Could it be not disengaging the drive and causing the engine to stall?

[Dead Eye]

The clutch should be fine but its near impossible to adjust if the engine cuts out when its in gear. Exup rode the bike home and reported no clutch issues and it hasn't been touched since

[Skippernick]

Chain tension, if its too tight would it cause a stall?

[Dead Eye]

But if the clutch is in then the engine shouldn't engage and the wheel wouldn't move - but the chain doesn't appear too tight. Looks as though it might be too loose if anything

[ChristoT]

But if the clutch is in then the engine shouldn't engage and the wheel wouldn't move - but the chain doesn't appear too tight. Looks as though it might be too loose if anything

Could something be blocking the front sprocket? Is the clutch disengaging properly?

[Dead Eye]

To be honest I really don't expect it to be a mechanical fault due to one test that I did

- Engine off, in 1st, clutch pulled in - won't start

[elbrownos]

Have you got Yamaha Fazer 600 (1998 - 1999) Service Manual?
http://www.archive.org/download/http://archive.org/details/printermanual-yamaha-fazer-fzs600-service-manual-1998
Chapter 8 has some detailed electrical troubleshooting instructions

[unfazed]

To be honest I really don't expect it to be a mechanical fault due to one test that I did

- Engine off, in 1st, clutch pulled in - won't start

Bike has to be in neutral if the the side stand down to start.
With the bike in gear, the side stand must be up and the clutch must be pulled in to start.
Since it starts in neutral and the side stand tests correctly then the next test must be the clutch switch
Bypass the clutch switch by removing the wires to the clutch switch and connect them together with a piece of wire.
Does the engine start? If it does replace the clutch switch.
 

[robby boy]

To be honest I really don't expect it to be a mechanical fault due to one test that I did

- Engine off, in 1st, clutch pulled in - won't start

Bike has to be in neutral if the the side stand down to start.
With the bike in gear, the side stand must be up and the clutch must be pulled in to start.
Since it starts in neutral and the side stand tests correctly then the next test must be the clutch switch
Bypass the clutch switch by removing the wires to the clutch switch and connect them together with a piece of wire.
Does the engine start? If it does replace the clutch switch.

Have you tried starting the bike with the side stand up, if it should start try engaging gear (with side stand up) it should not stall, also if you have a centre stand try engaging gear with the bike on the centre stand and the  engine off, try turning rear wheel it should not turn, now pull in clutch, wheel should now turn.
 

[Fazerider]

It's certainly behaving like the side stand switch isn't working. Since you've proved the switch itself is OK then I'd guess the fault is either the wiring/connectors between the switch and the starting circuit cut-out relay... or the diode in the relay assembly itself.

[Dead Eye]

To be honest I really don't expect it to be a mechanical fault due to one test that I did

- Engine off, in 1st, clutch pulled in - won't start

Bike has to be in neutral if the the side stand down to start.
With the bike in gear, the side stand must be up and the clutch must be pulled in to start.
Since it starts in neutral and the side stand tests correctly then the next test must be the clutch switch
Bypass the clutch switch by removing the wires to the clutch switch and connect them together with a piece of wire.
Does the engine start? If it does replace the clutch switch.

Have you tried starting the bike with the side stand up, if it should start try engaging gear (with side stand up) it should not stall, also if you have a centre stand try engaging gear with the bike on the centre stand and the  engine off, try turning rear wheel it should not turn, now pull in clutch, wheel should now turn.

Yes, bike starts fine on the centre stand with the side stand up - when you try to engage a gear, it cuts out

Didn't think about trying to move the rear wheel with the engine in gear and clutch pulled in so thanks for that tip

[simonm]

Does the engine die when you pull the clutch in or when you move the pedal after the clutch is pulled ? (I'm guessing when the clutch is pulled by the comments).  If so when during the clutch pull does it die and does it make a difference how slowly you release it ?

On the centre stand, if you release the clutch slowly does the rear wheel start to spin ?

When the engine dies is it a splutter/reluctant die or is it an electrical cut out ?

[Dead Eye]

Nope, engine dies as soon as it is kicked in to gear

Can't test on the centre stand for drive to the rear wheel as the engine cuts out - this is actually what my initial test was supposed to be to make sure the bike was running ok BEFORE I tried to set off on it :P

Seems pretty instant so I'd suggest it is an electrical cut out. I tried holding the revs up a bit and then kicking it in to gear with no joy

[simonm]

I'd say it was the neutral sensor rather than the clutch or side stand switch in that case ?

When did it start happening ?

All guesswork, I know nowt.

[Dead Eye]

Surely if it was the Neutral sensor the the bike wouldn't start at all? In my case, if I put the bike in Neutral the green light shows up to indicate this and I can start the engine

Well I guess it technically started as of yesterday?

Bike crashed just over 4 weeks ago - it was ridden home and then garaged whilst I did work on it. In this case the work involved swapping out the nose cone and light unit and replacing the forks. I haven't done anything electrical