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Blood Sweat Tears and Grease => HELP! 1-800-CAFE-HELP => Topic started by: jxcktheripper on Mar 28, 2014, 12:23:25

Title: Xs750 not starting after changing handle bars
Post by: jxcktheripper on Mar 28, 2014, 12:23:25
Hey everyone, brand new to the site and just bought an xs750 last night. I don't know what went wrong.. All I did was swap out the stock bars with a more cafe style bar. The bike was working relatively fine prior to this and started up no problem. I unscrewed everything and slid all the controls off and then back onto the new bars. The cables are a bit long for the new handle bars but I got everything back on and bolted down and was gonna take it for a test ride but it wouldn't start. All the electrics still work (lights, signals, gauges etc.) but the starter button won't start. I kick started it after a few tries but started at a really high rpm and I smelled like a burning smell so I turned it off. I'm pretty new to bikes and really bummed that this is happening, if anyone can help I'd greatly appreciate it. Thanks!
Title: Re: Xs750 not starting after changing handle bars
Post by: Bozz on Mar 28, 2014, 12:28:28
Some handlebar controls ground THROUGH the bars, so be aware if your risers attach with rubber vibration isolators (many Yamahas do) the handlebars may not be electrically connected to the chassis ground.  Often there is a washer on the bottom of the riser mount with a wire that connects back into the harness to bring the ground connection to the bars.  You may have disturbed this during your bar upgrade.


This is one possibility.  There are others.  Electrics are all about details and logic.  Patience is key.


Good Luck!




Title: Re: Xs750 not starting after changing handle bars
Post by: plagrone on Mar 28, 2014, 12:49:59
Another possibility is that when you were changing the bars, you strained the wiring and ripped the starter button wire out of its solder or connector, and that the high-revving and burning smell could just be psychological  ;D
Title: Re: Xs750 not starting after changing handle bars
Post by: jxcktheripper on Mar 28, 2014, 12:52:26
Thanks bozz that might be the problem. I just tried kick starting it and it started but it still revs at a high rpm there's a burning smell that wast there before? Any ideas?
Title: Re: Xs750 not starting after changing handle bars
Post by: jxcktheripper on Mar 28, 2014, 12:55:11
Plagrone crap.. How would I check that?
Title: Re: Xs750 not starting after changing handle bars
Post by: jungalist on Mar 28, 2014, 13:16:06
Plagrone crap.. How would I check that?

unplug the connectors from the harness and multimeter the shit out of them
Title: Re: Xs750 not starting after changing handle bars
Post by: Rich Ard on Mar 28, 2014, 13:19:20
multimeter the shit out of them

HA HA HA
Title: Re: Xs750 not starting after changing handle bars
Post by: Maritime on Mar 28, 2014, 13:28:31
the High RPM's sounds like the now too long throttle cable is binding and your cable is not letting the throttle close completely, the burning smell could be another wire or cable that is now too long making contact to a hotspot like exhaust etc. When you lower bars you need to make sure the cables run smoothly without any sharp bends etc.  Shorter cables and new zip ties for wires to keep them out of harms way is best.  IF short t-cable and clutch cables are too expensive, make sure you check the runs and re-run them differently to keep the bends smooth and check for binding when you steer full lock to lock etc.  and if starter button is broke you can test it in less then 30 secs with the conductivety/resistance part of your multi-meter, put a contact on each wire going in and out of the button, push button does meter move? no look for a broken wire or contact, if meter shows a change, button is good, move to the next place there is a connection, rincse repeat.
Title: Re: Xs750 not starting after changing handle bars
Post by: jxcktheripper on Mar 28, 2014, 13:34:28
the High RPM's sounds like the now too long throttle cable is binding and your cable is not letting the throttle close completely, the burning smell could be another wire or cable that is now too long making contact to a hotspot like exhaust etc. When you lower bars you need to make sure the cables run smoothly without any sharp bends etc.  Shorter cables and new zip ties for wires to keep them out of harms way is best.  IF short t-cable and clutch cables are too expensive, make sure you check the runs and re-run them differently to keep the bends smooth and check for binding when you steer full lock to lock etc.  and if starter button is broke you can test it in less then 30 secs with the conductivety/resistance part of your multi-meter, put a contact on each wire going in and out of the button, push button does meter move? no look for a broken wire or contact, if meter shows a change, button is good, move to the next place there is a connection, rincse repeat.
That really cleared up a lot of questions I had. Thanks man!
Title: Re: Xs750 not starting after changing handle bars
Post by: Maritime on Mar 28, 2014, 13:35:07
No prob, I made all those mistakes the first time I put lower bars on LOL
Title: Re: Xs750 not starting after changing handle bars
Post by: jxcktheripper on Mar 28, 2014, 13:43:48
No prob, I made all those mistakes the first time I put lower bars on LOL
haha yea I tried to save money and do it myself -_- ill post some pics so you can see the cables too
Title: Re: Xs750 not starting after changing handle bars
Post by: jxcktheripper on Mar 28, 2014, 13:56:40
@maritime
Title: Re: Xs750 not starting after changing handle bars
Post by: Maritime on Mar 28, 2014, 14:10:29
Yep your throttle cable is bent way too much that will make the reving issue, also your starter probably doesn't work cause the bars are painted and Yamaha grounds controls on the bars, sand paint off under the controls and that should fix it.  your cable needs to gently arc, tight curves are a no no.
Title: Re: Xs750 not starting after changing handle bars
Post by: Maritime on Mar 28, 2014, 14:14:15
You will have to disconect the throttle and likely clutch cable and find a new route for them. the 2 red circles are real bad bends for the throttle.  Also the loop on your clutch cable is too tight as well
Title: Re: Xs750 not starting after changing handle bars
Post by: jxcktheripper on Mar 28, 2014, 14:14:28
Yep your throttle cable is bent way too much that will make the reving issue, also your starter probably doesn't work cause the bars are painted and Yamaha grounds controls on the bars, sand paint off under the controls and that should fix it.  your cable needs to gently arc, tight curves are a no no.
ah! I knew it! Lol my gf was saying that last night too but I being stubborn and a man and trying to force it -_- ahaha thanks man! I'm just gonna switch them back until I can actually get it done properly. Do you know how much that might cost at a shop?
Title: Re: Xs750 not starting after changing handle bars
Post by: jxcktheripper on Mar 28, 2014, 14:17:52
Damn! Lol I had that gut feeling saying it was wrong last night but I ignored it cuz I wanted to look cool ahaha
Title: Re: Xs750 not starting after changing handle bars
Post by: Maritime on Mar 28, 2014, 14:25:17
not really, I do all my own stuff, make mistakes, learn, fix, move on LOL. I would look into if there were other models of the bike that came with lower bars from the factory and get the cables for that bike, or Motion Pro can make up cables.  Really not hard to re-route the current, just make gentle arcs, not tight turns.  I used the full length cables on my GL but put much lower bars what I did was make the cables go out away from the bars then curved them back towards the frame and crossed them over to the opposite side they were originally on and that made the difference. If I get the chance I will take a pic to show you what I mean.
Title: Re: Xs750 not starting after changing handle bars
Post by: plagrone on Mar 28, 2014, 14:31:53
ah! I knew it! Lol my gf was saying that last night too but I being stubborn and a man and trying to force it -_- ahaha thanks man! I'm just gonna switch them back until I can actually get it done properly. Do you know how much that might cost at a shop?

Don't do thaaaaaaaat, it's easy. You've already done most of the hard work. All you have to do is disconnect some cables and reroute them, slide the right controls off a bit and sand where they contact the bars.

Besides, shops are too expensive
Title: Re: Xs750 not starting after changing handle bars
Post by: jxcktheripper on Mar 28, 2014, 14:33:11
Hahaha that's a way to do it! I just wish I had more tools and a shop to learn in lol and alright I'll try that. All of this stuff is like another language right now I'm gonna try to get a friend of mine to help as well! Thanks again for the help man I really appreciate it. I'll keep you updated about the progress too!
Title: Re: Xs750 not starting after changing handle bars
Post by: Maritime on Mar 28, 2014, 14:33:54
found a pic, not sure you can see it but the cables are the ones from the apehanges the GL comes standard with and  I put the Euro superbike bars on.,
Title: Re: Xs750 not starting after changing handle bars
Post by: jxcktheripper on Mar 28, 2014, 14:37:33
Don't do thaaaaaaaat, it's easy. You've already done most of the hard work. All you have to do is disconnect some cables and reroute them, slide the right controls off a bit and sand where they contact the bars.

Besides, shops are too expensive
yeaa that's true.. Lol imma give it another go and I'll let you guys know how it turns out! Thanks mate!
Title: Re: Xs750 not starting after changing handle bars
Post by: jxcktheripper on Mar 28, 2014, 14:38:32
found a pic, not sure you can see it but the cables are the ones from the apehanges the GL comes standard with and  I put the Euro superbike bars on.,
oh shit! That makes a lot more sense! LOL thanks mate!
Title: Re: Xs750 not starting after changing handle bars
Post by: Maritime on Mar 28, 2014, 14:53:35
you can see how the clutch cable routes harder to see the 2 throttle cables but they do the same thing out past the headlight bucket then back into the frame to the carbs.
Title: Re: Xs750 not starting after changing handle bars
Post by: Maritime on Mar 28, 2014, 14:55:18
Also, when you get them routed, fire up the bike and make sure when you turn the bars lock to lock the engine doesn't rev up or the clutch leaver doesn't move as that means the cables are binding.  Bad news in a turn to have your clutch slip or throttle rev up on you.
Title: Re: Xs750 not starting after changing handle bars
Post by: jxcktheripper on Mar 28, 2014, 14:56:18
you can see how the clutch cable routes harder to see the 2 throttle cables but they do the same thing out past the headlight bucket then back into the frame to the carbs.
yeaaah I feel like that would work, I'm just afraid of detaching things and not being able to properly put them back
Title: Re: Xs750 not starting after changing handle bars
Post by: jxcktheripper on Mar 28, 2014, 14:58:13
Okay, will do! And yeah that'd be bad news lol
Title: Re: Xs750 not starting after changing handle bars
Post by: Maritime on Mar 28, 2014, 15:00:30
Got to learn sometime, cables do not last forever and knowing how to change them out is a good thing.  Get a manual too if you don't have one already.  Pretty easy to remove the cable from the bar control and clutch lever end, you can probably leave it alone at the carbs and clutch and just arc it out and back smoothly to the controls.
Title: Re: Xs750 not starting after changing handle bars
Post by: jxcktheripper on Mar 28, 2014, 15:02:15
Very wise words my friend lol I really appreciate the help! I'll try that.