electrical gremlin

[stu600cc]

Hope someone can help

I need a bike electrician to come have a look at my bike

As a few of you know ive had a problem with my bike

When i press the starter button the fuel pump turns over but not the starter motor
If i arche out the starter relay the starter motor spins along with pressing the starter button the engine fires.

I have checked as far as my electrical knowledge goes to whether or not there is a brake in the system and cant find none.

Ive changed the relay 3 times just to be sure

I was thinking about changing the starter lock out switch but power is going through so i think thats ok.

I cant uderstand why it wont work im really getting frustrated !!!!!!

Please some help me find someone who can help

[kasandrich]

I presume you have checked all the fuses Stu?

Do you have a workshop manual with a wiring diagram?

[DoodleBug]

Is there a clutch or sidestand safety switch which might not be working correctly?

[Lateshift]

I am not that familiar with the ZX6R engine but a few things here seem strange to me.

A. The fuel pump should prime when the key is set to 1st stage ignition and not when the start button is pressed?

B. If the ignition is set to 1st stage and you bridge the start-relay the bike should fire anyway, pressing the starter button shouldnt make any difference because you have already made the circuit 'live' by turning the key.

C. If you are having to use the starter button to actually create a circuit when the start-relay is bridged then there has to be a fault on the ignition circuit i would have thought, from the ignition to the ECU (including the starter switch), the circuit should all loop back to the ECU.

When you get the bike running Stu, does it run okay without any stalling or rough idleing??

[stu600cc]

Yeah it runs fine

The side stand switch is ok

Thats the thing without pressing the button and the arching the relay it wont fire

[Gramps]

Stu, if your bike is 00 - 02 model, I have a PDF manual (not Haynes) that shows the starter circuit wiring and has a pretty good fault finding bit if that's of any use to you, but you'd need a test meter.

[stu600cc]

I got a manual its g1 98 model courtesy of doodlebug the other year

This is the starter wiring diagram

I ve tried all the tests the only thing i think it could be is the lock out swithch as it seems to have 1 terminal live contiuous which is the earth but when the ign is turned on it has 3 terminals live . that cant be right can it?

http://img.photobucket.com/albums/v41/falloff/wiring.jpg

[Gramps]

Where are you Stu? PM me and I'll bring my test kit and have a look for you.

[stu600cc]

I have a tester and tested everthing

the only thing that has no power coming out to the starter relay is this box which is i think the starter lock out switch

http://img.photobucket.com/albums/v41/falloff/IMG_4308.jpg

[kasandrich]

I agree that is a relay.

The start control relay has 5 wires in the diagram, and according to the diagram the start control relay is in a junction box, is it definitely the right diagram for that bike?

[Gramps]

Sorry Stu, just deleted that earlier reply. Explains the wiring colour differences. I just looked up that part number and it's described as a Kawasaki Analog Tacho Relay. In another it's shown as the fuel pump relay and the wire colours in the circuit match those in your photo.

[stu600cc]

Ive looked it up on the net and in the micro fiche it says it a relay assy

[Gramps]

You need to locate the junction box that houses the starter circuit relay. If you can measure the voltages on the connections to that, they should be:
Brown wire: 12 volts constant
Brown/white wire: 12 volts constant
Black/red wire: 12 volts when you press the starter button
Yellow/red wire: 12 volts when you press the starter button
Yellow/green or is it grey? - voltage depends on resistance of relay coil and solenoid coil as they act as a potential divider, for example, if both resistances are the same then you would expect to see about 6 volts.
If you have 12 volts on the brown wire, but not the brown/white wire, the 10 amp fuse is blown.
If you have 12 volts on the brown/white, but not the black/red, the starter switch itself is faulty.
If you have 12 volts on the black/red and a smaller voltage on the y/g but none on the y/r, then the relay is faulty.
If you can locate the starter relay (10), check for 12 volts on the yellow/red wire when you press the start button. Also check that the black/yellow wire is a direct connection to the battery.
Remember though, that any of these could be a broken wire.

[stu600cc]

quote: Black/red wire: 12 volts when you press the starter button

Im not getting that but there is no break in the wire?????

[Gramps]

OK, try this...
Set your test meter to resistance, disconnect the battery positive lead. Connect the black test lead to the battery positive lead and the red one to the black/red wire, then press the start button and check what reading you get on the meter.
(The reason for connecting the test meter wires this way is because on the resistance range it puts out a voltage - positive out of the black lead - which if connected the other way round could damage your ecu)

[stu600cc]

what setting should i be on wat are the symbols

[Gramps]

Set the test meter on the lowest resistance range. There should be very little resistance measured.

[Gramps]

If you are getting a substantial resistance there, try this...
Reconnect the battery, then connect a piece of wire, one end to the battery positive terminal, turn on the ignition switch and touch the other end of the wire to where the yellow/red wire comes out of the junction box. The starter should operate.
If it doesn't, you have a fault with the starter relay (10).
If it starts, try doing the same again, but this time touch your test wire to the black/red wire where it goes into the junction box.
If it doesn't start, you have a fault with the starter circuit relay (5).
If it starts, try the same again, but this time where the black/red comes from the starter switch.

[belerathon]

Hope someone can help

I need a bike electrician to come have a look at my bike

As a few of you know ive had a problem with my bike

When i press the starter button the fuel pump turns over but not the starter motor
If i arche out the starter relay the starter motor spins along with pressing the starter button the engine fires.

I have checked as far as my electrical knowledge goes to whether or not there is a brake in the system and cant find none.

Ive changed the relay 3 times just to be sure

I was thinking about changing the starter lock out switch but power is going through so i think thats ok.

I cant uderstand why it wont work im really getting frustrated !!!!!!

Please some help me find someone who can help

where in south ock are you? pm me as i am in canvey island monday

[stu600cc]

Ther bikes actualy at my dads in harold hill Romford

I finish work about 4:30

[stu600cc]

Thankyou gramps

Had the master above have a look at the bike today and he managed to find that the problem was the lockout switch on the clutch lever that i had taken off wen changing the levers :shooter

[RaceMeNSee]

hrrrrrr....annoying i know....but at least its all sorted now mate!! also was nice to see you again the other evening! evan though we barely spoke! lol

[stu600cc]

simple things to fix glad its sorted

yeah next time ill make a bee line for you :cuddle