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baja designs kit 2007 wr450f

By rubberband-man,
in WR400F/426F/450F

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rubberband-man

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I just installed my baja designs kit, and I can't get the bike to start. I had to do the stator modification, but it was simple and i checked it with the ohmmeter and everything is good. Any ideas what might cause the bike to not start? i push the starter, and it just revs, but will not turn over. kick start is the same. please help!

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taycam

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are you saying that the starter is not turning the engine over? but the starter motor is just spinning? if yes then you may have installed the gear for the starter wrong when you had the cover off to do the stator mod. I beleive this gear has a one way clutch in it (to prevent to starter from exploding when the engine fires). Just take the little cover off, held on with two bolts and have a look

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MrMotorhed

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lots of people get starting terminology just wrong. turning over is when the crankshaft actually rotates for whatever reason. firing is the fuel burning in the engine and usually the engine running. revving is something the engine can only do if it's running.

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rubberband-man

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OK--Looks like I got my terminology wrong. The engine is turning over, the bike will just not start. It is as though it is not getting a spark. I tried the switch suggestion last night, but it apparently is not that. The woodruff key is intact, and the starter gear is installed properly. I really appreciate everyone's help. I am going take the kill switch off now--maybe my wiring is messed up. if anyone else has any suggestions, please help. All the guys that work in the YAMAHA factory must have tiny fingers. I'm trying to get to the spark plug, and am finding next to impossible.:busted:

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William1

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rubberband-man, you already bought the Baja and apparently made the stator mods and such. Did you do the tests as perscrided in the BD instructions, are you positive you did not pich a wire when you put the staor back on and the side cover? Are all the connections done correctly? I just installed the kit on a WR250F this week with no problems. I did get caught by not having the bar switch in the off position at first though! Now the bike has two things that must be turned on to make it run, a little more safe from a 'snatch and ride off' thief.

The DRC kits are seperate from the bikes electrical system and as such, is a 'total loss' battery (you have to replace or recharge them).

http://www.wheelingcyclesupply.com/

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taycam

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with the Baja Designs kit the factory kill switch must be removed and replaced by the the kill switch on the multifunction switch in the kit. One thing that has come to mind is when you were doing the stator mod you would have removed the "pick up coil", this is held on by 2 bolts. The pick up coil has 2 locating dowels on the bottom side of it in order for it to have the correct spacing from the flywheel. Make sure that these dowels are seated in their holes or the pick up coil will not get the signal pulse from flywheel rotating past it. No pulse = No spark.

TC

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taycam

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you could not be more wrong...my stock kill switch works great as well as the baja designs one

Well maybe your kit is different than the kit I just installed on my 07 WR..... on my kit the 2 terminal socket of the factory harness where the kill switch plugs into is now occuppied by a 2 terminal plug of the baja designs multifunction switch.....it explains it in the first paragraph on page 8 of their instructions.....

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rubberband-man

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so i disconnected the baja designs kill switch and tried to start the bike up---fired right up. i called baja designs and they told me to get a multitester and check the switch. i haven't done it yet, but after i fired it up, i plugged the bd switch back in and the bike wouldn't start. unplugged it again--and --vrrrroooom. thanks for all your help. this is a great forum.

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Justang

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Cool that it's just the kill switch.

My kill switch from the BD kit replaces the factory kill switch and where it's plug in. I also have the ignition/key as well.

One thing to watch out for is reinstalling your stator. I did the mod correctly and checked the resistance with my multimeter, perfect. But when I got the bike back together, it wouldn't start. After a day of checking everything on the bike and hoping it wasn't my CDI or their rectifier, I found the problem. When reinstalling the "wire holder" next to the stator I crimped one of the wires and grounded the entire system to the casing. DUH! :busted: I found it, and had to fix the wire and reinstall everything again. Fired right up. So the way to test for this is to check your resistance at the wire coming out of the casing. Anyway, just thought I'd share my experience (my dumb mistake) so that anybody who had the problem of not starting would check their stator and wires.

I did a lot of searching on TT and found many people don't like the BD kit. So far I love this kit. The only problem I had with it, I created.

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William1

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I like the BD kit too, only parts I found to be a pain were the mounting of the tail light inner fender to the fender and the regulator/rectifier install. Took a lot of time to get them perfect. A template for the fender and 8mm spacers for the RR instead of the 10.1mm ones would of made it so much easier.

I like the single bar switch. I like that now I not only have to push the Yamaha 'On' button but the lighting switch has to be in at least the 'Park' position, a little tiny bit of extra security against a "hop 'N rider".

My kit will not stay on the bike. It will be stored away and used only to do the yearly inspection and the occassional DS rides. I am going to mod the stock head light to be able to return it to use (will have the hi and low beams working) and I have already enabled the brake light function on the stock WR tail light.

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Justang

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Yes, I too like the added security. You have to have the ignition button pushed in, the light switch on, and I have to have my key in and on. True that'll only detour the joy riders, and if they are even slightly educated in bikes most of this can be bypassed. My real fear is two guys coming and picking the bike up and throwing it into the back of their truck.

I live in a small town though, I'm not worried too much. :busted:

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taycam

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I did a lot of searching on TT and found many people don't like the BD kit. So far I love this kit. The only problem I had with it, I created.

I went to all the manufacturers web sites and searched on here and found that baja designs was the best kit for me. I'm pleased with my choice as I found the kit to be quality built, the only things I would change is that it should include a 2nd brake light switch for the front brake and I think the tail light should be a little larger (for saftey reasons) other than that so far so good. With their instruction manual anyone could install it with ease,very comprehensive and easy to follow with pics that are right on the money

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