My '01 800 sat in the garage for about 1.5 years and now I'm trying to get her going again. I originally parked it because I was having turn signal issues, then just never got around to messing with it. I put Sta-Bil in the tank, had it on a battery tender and started it every couple months...for a little while. You know how things go. Battery tender got moved to the boat, battery died, then it didn't get started for many months... Anyway, since my wife's car has been in the body shop for 3+ weeks and insurance won't give us any more rental days, I figured I would fire the old girl up and ride her. Obviously that didn't happen .
So here's the issues I'm having, and I'm getting the feeling that they are all interlaced.
1. No starty-start. More on that below.
2. No horn. I can hear the relay click and the horn makes a noise, like it would if the battery is dead.
3. Turn signals both blink no matter which direction is on, alternating flashes.
I have the factory manual and the Clymer manual and have been going through that.
So far I've:
- Checked all fuses (visually & for continuity)
- Charged the battery. Still sounded weak when cranking though.
- Tested signal generators - OK
- Tested for spark. Only getting intermittent spark it seems. Nothing when the starter is cranking. Let off the button and BOOM spark plugs be sparkin'.
- Swapped in new NGK's
- Tested for voltage at the coils - 6-ish volts. No bueno.
- Replaced the battery with a new one. (With star washers! I know enough about Intruders to know that if you have a flat tire...it's probably because you don't have star washers on the battery ). Same intermittent spark. 9-10v at the coils when cranking.
- Cussed
- Ohm-tested both ignition coils and replaced them. They tested out of spec when cold, but ok when warm. No change.
- Cussed some more
- Tested side stand switch - OK
- Tested neutral safety switch - OK but nasty. My clutch slave leaks, which is right above the NSS. It will get replaced when I rebuild the slave but it seems to be working fine.
- Tested clutch switch - OK
- Tested the kill switch - OK
- Checked fuel pump relay - Relaying
- Checked fuel pump - Pumping. A funny thing about that...I had the pump disconnected and fuel hose off, tried to crank it for grins and giggles and the dang thing caught and sputtered for a second then died.
- Cussed, dropped tools & went to be in disgust
So that's where I'm at. Not sure where to look next.