4:30am wrapped up and went out to start Natasha. -15C and anothe 15 degrees of windchill. After kicking the engine over a few times she gave one cough but using the kicker was obviously not ging to work Hey that is what electric start is for, right? Uh Uh ... started button frozen solid. I guess some moisture must have got in and frozen. Later in the day I warmed it up with a heat gun till it would work and tried to get WD40 in, but tonight it is frozen solid again. Tomorrow I will have to go exploring inside the switch housing for the first time and see what gremlins lurk in there Heat! we need heat

Is your bike outside or in an unheated garage? If in a garage, park a 100W trouble light under the oil pan the night before you want to ride. It will make cold starts a lot easier. As for the switch housing, once it is split you still won't be able to directly access the start button without disassembling it, but a few well aimed squirts of WD-40 will solve the issue. I usually open up both switch housings in the Fall and coat them with WD-40, haven't had any problems since. Also, I find the plastic hand guards really help cut down on the amount of moisture that gets in there.

Take your least favorite wrench and approach the starter solenoid.
Touch one part to the large stud with the battery cable.
Touch another part on the small stud.

You have just made the same connection that the starter relay does.
You have managed to bypass all safety features of the relay system.

Your bike is now running.

You have minor arc marks on your least favorite wrench.

Thanks for the suggestions guys. Natasha sits outside all year (the 72 Honda CB 500 and the snow blower take up all the available space in the garage). I did think of shorting out the solenoid but at that early hour I am a bit fumbly and had a vision of a wrench or screpdriver welded alcross the connections.

Anyway today took a look inside the handlebar cluster, but as suggested the problem is obviously inside the switch.. However I did notice that on the underside edge of the starter button there are two small slots, still accessable from the outside when the cluster is all tightened up. A small shot of alchohol based antifreeze in the slots freed things up and was followed by a couple of shots of WD-40. The weather is warmer but still below zero and all seems well. I will find out for sure on Friday. I love winter riding!

Happy New Year everybody .... may your gremlin bells all ring merrily!

[quote name='scuba_u' date='Dec 30 2009, 02:32 PM' post='112137']
4:30am wrapped up and went out to start Natasha. -15C and anothe 15 degrees of windchill.

SOLUTION : Visit OZ - already had 40+C !!

Happy & safe New Year

Yeah, but where's the fun in that?!

In severe cold, or the day it won't start, slip a med sized paper bag over each cylinder, tear a cornor out of each, plug in an old hair dryer, insert thru hole, about 2-3 min on each side, .......remove bags before riding .....From -10 F. Wisconsin.....Ken

Hey! Now that´s a clever idea!