FC250 Husky Wiring and E-start problem

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7/21/2020 8:54 AM

Can someone post the colors for hookup of the e-start button on a 2017 FC250?

I just picked up this bike used and the e-start button has been ripped/disconnected. I have two torn wires on the button side and two on the bike side and I tried twisting them together in both combos and had no fire from the e-start.

The bike bump starts, runs good, and the battery has a built in life indicator, and it's showing fully charged.

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KTM250SX YZ125 YZ85 PW80 ZX6 FZX700

7/21/2020 8:59 AM

Photo
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KTM250SX YZ125 YZ85 PW80 ZX6 FZX700

7/21/2020 9:01 AM

Photo
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KTM250SX YZ125 YZ85 PW80 ZX6 FZX700

7/21/2020 12:40 PM

have you checked the fuse then try the wires again?

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7/21/2020 1:07 PM

CarlinoJoeVideo wrote:

have you checked the fuse then try the wires again?

The two 10A fuses beside the battery? Yes, checked those last night too and they were fine.

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KTM250SX YZ125 YZ85 PW80 ZX6 FZX700

7/22/2020 9:10 AM

I didn't have any measurable DC volts/power at the kill switch, but I was able to start the bike by jumping the relay.

The power was being blocked by the relay.

So I pulled out the relay and did the 12V test and am getting no click. So I'm ordering a new relay.

It took my stupid a** a long while to figure that out, but I think I've found the problem smile.

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KTM250SX YZ125 YZ85 PW80 ZX6 FZX700

7/24/2020 4:53 PM

Still no start … bump if you have any ideas.

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KTM250SX YZ125 YZ85 PW80 ZX6 FZX700

7/24/2020 6:52 PM

Check ground points

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7/24/2020 10:21 PM

I’m confused on what wires are torn. Maybe better photos would help us? Not enough info as is.

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7/24/2020 10:25 PM

Factor E wrote:

Check ground points

It’s a FC250 so the earth strap runs to the coil instead of the subframe like the KTM.
Cleaned and confirmed negative battery terminal connection and coil mounted earth.

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KTM250SX YZ125 YZ85 PW80 ZX6 FZX700

7/24/2020 10:29 PM

CarlinoJoeVideo wrote:

I’m confused on what wires are torn. Maybe better photos would help us? Not enough info as is.

I figured out by referring to the manual that one 10A fuse is active on the red side of the relay. the other on the black side is a spare. Both fuses looked fine but one was not continuous so dead . Despite finding this and confirming 10a fuse is good, still no crank.

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KTM250SX YZ125 YZ85 PW80 ZX6 FZX700

7/25/2020 12:28 AM

The connector in the picture looks like the FI indicator
better picts

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7/26/2020 8:45 AM

I just straightened out an older ktm product the e-start didn’t work. I started at the source, and kept testing things until I found all the problems. As factor e stated the rubber plug you’re holding should plug into the socket for the FI light next to the trip meter if your bike has it. It is an LED.

Start by checking the condition of the battery. Then test the starter itself. You can use a jump pack or another battery. Ground to the starter case, positive to the B+ post. If the starter spins and the battery condition is ok, make sure you have B+ at one of the big terminals on the start relay. If you do, and the ten amp fuse is good, check the connector going into the starter relay. Usually three very small wires. They are prone to breaking. If they’re broken, you’ll have to get that straightened out.

Finally, the two bare wires you’re holding should correspond in color to two of the wires going into the starter relay connector. Once you have everything squared away in the system, shorting the two wires together on the chassis side, not the switch side should activate the starter. I eliminated the switch connector on mine since the wires were broken right at the round terminals.

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8/18/2020 12:22 PM

Update on this thread: there are a lot of grounding/earth problems on these bikes, and even though I cleaned the ground strap connections and confirmed continuity with a volt meter, I went one step further and jumped the earth terminal to the cases. For those of you with starting issues, also try this trick. Unfortunately, it didn't help me and the bike still wouldn't start.

I replaced the starter relay w a new genuine KTM unit and kept chasing other issues and eventually got frustrated and gave it to my friend to look at. He double checked the new relay and found it to be faulty. A second new KTM relay fixed the problem and now it starts first push of the button!

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KTM250SX YZ125 YZ85 PW80 ZX6 FZX700