so... i blew my engine, ang got lucky finding a low milage, same year engine for a resonable price. got mine out, got new one in, reconected everything (cheked kev's guide, all done proper), and it just turns over and doesn't start. has spark, fuel pump's working. now, since 2 days ago (and me bickering around it, trying this and that) i have a new problem added. headlight stopped working (only works in diagnostic mode, and with flash button) and horn is a bit shy... you need to keep it pressed for 3sec to start it. diagnostic reports no problems (exept for battery voltage sometimes dropping to 0.0, but since it cranks, i don't suppose it's a problem). i'm out of ideas (and so is my father, who is mehanic with his on workshop). tried going to shop with it, but it only got all the workers scratching head around the bike. any help guys? btw, bike is xt660x from 2005.

With XTs the age of yours the wiring and connectors will almost certainly be past their best. It is well worth going over all the connectors and checking for corrosion and poor contact, including the battery and coil connections (HT and primaries). Particularly check the multiplug on the main relay unit behind the right hand side panel. This can be the cause of a lot of weird electrical gremlins.

When you disturb connectors that have been in place for a long time they almost always don't reconnect cleanly. Break and remake them, cleaning as you go. Brake cleaner and a toothbrush are very effective.

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i have had bad plug contacts a couple times..
I use CRC Lectra-clean.. electrical contact cleaner...




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Harley Davidson..
The easyest way to turn gasoline into noise with out the side efect of horse power...

well, it's not connectors... that was my first guess, cheked and cleaned all of them, chek all wires for some damage... tested for breakings, all i cloud think of. -.-' quite confident they are ok...