Won't start hot. neutral light / temp sensor swap?

[parrmich]

Hey all,
Backstory: Base gasket was leaking, rebuilt the engine in my garage, took about a month. Bike runs great now with one exception:
When I turn the bike on first thing in the morning: the neutral light is on, always, no matter what gear it’s in. But, after about 15-20 minutes of riding the neutral light turns off and won’t turn on again, no matter what gear it’s in (or not in).
I would just ignore it, except that if I take a long ride, turn the engine off and walk away…then come back 5 minutes later: the bike won’t start because it thinks it’s in gear!
Is there a temp sensor I could have switched with the neutral indicator or something? Any ideas why this is happening?
Thanks!
Mike

 

[Chicknstripn]

What year is your bike? Is your bike equipped with the side stand cut off switch?
Pull the front pulley cover and check the connections there.
Also, make sure the neutral detent switch, located at to the top rear of the front pulley behind the belt, doesn't have any broken or loose connections. Actually, check that it's torqued down correctly.
If all those things are good to go then I'm at a loss.
You might want to check your service manual for trouble shooting procedures.
Good luck

 

[user_deleted]

mike: what chickn said above. he always provides excellent info. the neutral light switch is behind your front belt pulley and believe it or not can be swapped out for new without removing pulley. tedious but possible. they are cheap money and when faulty provide all the symptoms you're describing. i never clean them and hope for the best....just replace it and good to go.

 

[Chicknstripn]

Thanks for the props lunatic! Means more than you know coming from the ole wise one!
Report back on what you discover Mike. It helps for those that may stumble upon this thread in the future!

 

[parrmich]

Thanks so much for the help you two! I'm actually in the middle of the michigan's advanced motorcycle safety course right now, it won't be over until 9PM tonight (after work-class), then I can get to work on this. I'll let y'all know, in the mean time, THANKS SO MUCH!

 

[parrmich]

The bike is an 2004 XB12R Firebolt, forgot to include that. It does not have the stand kill-switch.

 

[parrmich]

Well, I guess I can't upload photos from my phone. But, you guys were right. After downloading and printing the service manual it has me test the neutral switch cable by grounding it out. The connection to the cable was good, so it must be the neutral switch itself.
I'll be shopping for a new one soon, or maybe I'll just bipass it and always have a neutral light.
Thanks for the help everyone. You've been great.

 

[user_deleted]

or maybe I'll just bipass it and always have a neutral light.

very bad idea. i don't know all the nuances or specifics regarding codes and programming but your bike via the ecm will act up. replace the switch. any H-D dealer will have it or can order it up for you. comes with new gasket which is mandatory. double check when ordering but oem part # should be....33900-99

 

[parrmich]

Lunaticfringe, I had no idea! For $12 though, totally worth it.

 

[user_deleted]

^^^^ my pleasure. do you know how to loosen rear wheel....remove tensioner...remove front pulley cover....and access the switch? i mention this as service manual will have you doing all this along with front pulley removal but you can cheat on all that and do the switch swap.

 

[parrmich]

I pulled my engine last month ( replaced a leaking base gasket), so I've pulled everything except the pully before. It's not too terrible.
But what do you mean cheat all that? Can I get it out without pulling off the pully?
I'm amazed that the Harley dealer in Detroit doesn't carry the switch...[mad]