Starts and runs, when shifted in gear - dies...help

It's 09 and kickstand switch is bypassed, gear switch/sensor is working fine...Is it possible it's one of the relays or maybe clutch switch? Need input from collective....thanks

not a clutch switch related!

Did you just do the kickstand switch bypass?

I'd check that whole situation.

Sounds exactly like what should happen if you click into gear with side-stand down.

Checked kickstand deal - no issues
Still puzzled

How long has the bypass been there? Did yo just do it? Or has it been that way for a long time?

was there for a while...

Can you describe exactly what's happening?

Can you start bike in gear with clutch pulled in?

Does bike die the second you tap gear shift into gear, or when you apply throttle and start to let clutch out?

Are you sure your clutch cable doesn't need adjusting?

Somewhere around this forum is a thread on a bike dying.
There's a plug behind the radiator that if loose does strange things.

I would still triple and quadruple check the wires for kickstand switch.

Make sure they haven't rubbed through and are shorting some place.

It sounds like the bike thinks the kick-stand is down.

Unless there's other details you can pass along....

Sticky...damn....

click me <-- finally found it.... a sticky for pete's sake...

I will check that plug...meanwhile....this is the whole picture...
Bike is on stand, wheels removed (changing tires)...
Ignition key in ON position, lights up/gauges fine/fuel pump primes.
It's in neutral, i'm able to start the bike (without clutch lever engaged), runs and revs fine. Moment
i engage clutch and shift into gear - instantly dies. Neutral sensor works (in neutral lights up N light, when in gear - doesn't - not sure if that is indication of being 100% operational) No faulty codes on gauges whatsoever....

Have you tried starting bike while in gear, but with the clutch pulled in?

Edit to add: So, I just went out in my garage and checked.

It is possible to start the wr250x when in first gear with the clutch pulled in.

My vote is for chaffed wires from the kickstand switch. Trace them bastards back to the ECU and make sure they are still in good shape.

Arkmage wrote:

My vote is for chaffed wires from the kickstand switch. Trace them bastards back to the ECU and make sure they are still in good shape.

+ 1 on the kickstand swicth wires.




Also, don't overlook something silly.

I chased a KTM carb problem for a couple months. Everytime I stood the bike up off the side stand, it would pop and fart. I swore up and down it was in the carb.

The night I gave up on pulling the carb apart (8 times), and replaced it with new. I found a short in the wires coming off the handle bars. When I would lean the bike up, I would turn the bars straight at the sametime, creating the short

Also - I just checked this.

With bike on side stand, in gear, and clutch pulled in.....won't start.

So if you're bike, with no wheels, on center stand, and in gear, won't start with clutch pulled in and side stand up....I'd look at that by-pass and the wires.

Please try this:
Bike in Neutral, kickstand up (if you have a switch), ignition ON and without pulling a clutch try starting the bike.
I can start it like that....can you?
(going to check that mother..)

trigger33 wrote:

Please try this:
Bike in Neutral, kickstand up (if you have a switch), ignition ON and without pulling a clutch try starting the bike.
I can start it like that....can you?
(going to check that mother..)

Mine starts like that with no issues.

Just tried it.

Again.... can you start yours in gear with clutch pulled in???????

In gear and clutch pulled in - nothing happening. Fuel Pump works, gauges light up but nothing....

motokid wrote:

Have you tried starting bike while in gear, but with the clutch pulled in?

Edit to add: So, I just went out in my garage and checked.

It is possible to start the wr250x when in first gear with the clutch pulled in.

motokid wrote:

Also - I just checked this.

With bike on side stand, in gear, and clutch pulled in.....won't start.

So if you're bike, with no wheels, on center stand, and in gear, won't start with clutch pulled in and side stand up....I'd look at that by-pass and the wires.

motokid wrote:

trigger33 wrote:

Please try this:
Bike in Neutral, kickstand up (if you have a switch), ignition ON and without pulling a clutch try starting the bike.
I can start it like that....can you?
(going to check that mother..)

Mine starts like that with no issues.

Just tried it.

Again.... can you start yours in gear with clutch pulled in???????

trigger33 wrote:

In gear and clutch pulled in - nothing happening. Fuel Pump works, gauges light up but nothing....

Check the kick-stand by-pass, and then trace the wires from that by-pass all the way back to where-ever they end.

What you've stated, and what I did with my bike shows that your bike assumes kick-stand is down when you click into gear.

check the starting circuit cut-off relay (behind the rear left shroud, where that exup wiring exists)...
without removing it, jump the Blue/Yellow wire and the Blue/Green wire, effectively bypassing the kickstand/clutch/neutral combo...
if it works, the relay is at fault...if it doesn't, this is a good time to confirm that the kickstand switch bypass is good (Blue/Green to ground)...
remember to remove the jumper when done! or else the bike will start in gear-no clutch...

Fuzzy Wrench wrote:

check the starting circuit cut-off relay (behind the rear left shroud, where that exup wiring exists)...
without removing it, jump the Blue/Yellow wire and the Blue/Green wire, effectively bypassing the kickstand/clutch/neutral combo...
if it works, the relay is at fault...if it doesn't, this is a good time to confirm that the kickstand switch bypass is good (Blue/Green to ground)...
remember to remove the jumper when done! or else the bike will start in gear-no clutch...

I just did (another) BYPASS per your instructions....and it worked! Bike starts in Neutral, clutch IN, shift in gear - still runs!!! Looks like we have a faulty relay...and best place to get it fast IS?
Thank you all for your input and time spent on figuring this one out....
Just installed BFN 244's and can't wait to hurt myself!

Tip fir future. Instead of skinning wires like that (leads to corrosion/oxidation of the wire and poor electrical performance) just get a jumper wire skinned at both ends and poke them into the holes in the back of the multi plug where the normal wires go in

Make sure you tape those skinned sections up well to reduce water and dirt ingress