I have a 2001 Savage (15K) that I currently use for a "winter beater" bike, which I typically just ride from Nov. thru Feb. here in NE Ohio. It will see 6-7000 miles during those months, and it gets ridden in all of the nasty weather. Twice this season I rode somewhere, and then the engine would not crank when it was time to go. At home, it is stored in an unheated barn, and always starts easily when I want to go somewhere.

First time, I rode it 12 mi, temp was -6F. It sat for maybe 5 minutes before I returned. Hitting the start button resulted only in a relay click. Headlights were bright, even when trying to start it. Pushed it inside the shop for an hour to warm it up, and it fired right up.

Second time, about 4 weeks later (and numerous successful sub -zero starts), I rode it about 2 miles, temp was -10F. It sat for about 3 hours, then again, only relay clicks. Tried to jump it from a truck - just clicks. Pushed it home.   I left for Guatamala the next day, so the bike sat for 2 weeks, with temps mostly 0 to -30F. The day of my return, it warmed up to 5. I gave the bike a try and again, it fired right up. It just sat the whole time, no battery charge or anything, so I would think that weather would have polished off a weak battery. That was back in late Jan, and I have ridden it over 1200 miles since then without incident.

Connections all looked good, but I cleaned them anyway. Bike is basically stock, but I have added a large windshield, Hippo Hands, and heated gloves for winter comfort. The gloves were not accidentally left on either time. I have had occasional trouble with the ignition switch being hard to turn because of salt and road grime, but a good cleaning takes care of that problem.

My only thought is maybe moisture freezes something up, or prevents a contact from being made? But then, I would think any temp below freezing should be a problem. I can't say as I want to troubleshoot a bike out in sub-zero temps, but it works fine otherwise. Hopefully we are done with the below zero stuff for this winter.

Anyone else ever have this problem? Any suggestions as to what the problem might be? I've ridden other Savages throughout the winter, and not had this problem with them. My apologies for the lengthy post.

I'd suspect the solenoid.

. Hitting the start button resulted only in a relay click.


So, a spot on the heavy contact is arc burned..

multiple potential causes.

mechanical-could be cold enough to seize up the starter gear-steel vs. aluminum thermal contraction.

electrical-I don't think it's the safeties, you wouldn't get the 1st click if it was.

relay is more or less sealed but should just be a spring and a magnet.

decomp controller is only semi sealed and we know water has gotten in there before and kicked in the starter in the middle of the night.

I'd put a volt meter on the starter post to see if it were getting juice.
If it is, then it's most likely mechanical.  replace the starter torque limiter washers with really thin ones.  They're pretty thin already.

One way to do an easy check, is to wire a light bulb between the positive cable connection on the starter - other end to the ground.  You could just temporarily mount the light anywhere that you can easily see it.

If you hit the starter button and nothing happens - look at the bulb.  If the bulb is not lit the electricity is not going to the starter.  If the bulb is lit and the starter is not moving...then the starter has an issue.  

If you don't have a '95 or later, or have added the torque limiter to your bike, you risk serious damage backing up your bike in gear.
That said, unless you have a free spinning starter, backing it up probably won't spin it anyway.

Serowbot wrote on 03/18/15 at 07:32:55:


Seriously, this is some extreme riding conditions.

In my 20's I would ride down in to the 20 degree range. In my 30's I'd ride into the 30's. In my 40's...well...you do the math...I'm in my 50's now.

No way I'd ever think of riding into this range.

There have been some excellent suggestions/reasons for my issue, and I have printed them out to keep on record. Again, I thank each of you for taking the time to reply. The only problem now is that I suspect I will have to wait until next winter for it to get cold enough for the problem to recur. If it does, I think the first thing will be as suggested, see if the starter is getting power. That will tell me which direction to proceed. I also did not know about pushing the bike backwards to jog positions of things, so I will definitely keep that in mind also.

Being a mechanical engineer, verslagen1's potential cause of the dissimilar metal contraction rates possibly causing a bind is along the lines of what I suspect, but not sure what to do if that is the cause (some other riders frequently just leave their bikes running during relatively short stops).

Serowbot & Gary - My only heated apparel is a pair of gloves, as my hands are all that ever got cold. Usually I don't turn them on unless it is below freezing. The Hippo Hands are great for keeping the cold wind from having much effect. As far as age, I am a bit north of 60, and have been riding year 'round since I got my first street bike 42 years ago.