Gen 1: 2004-2005 Electrical 101 Guess the Problem - Kawasaki ZX-10R.net
 
LinkBack Thread Tools Display Modes
post #1 of 4 Old 07-12-2014, 07:16 PM Thread Starter
Bloo Moderator
 
bluedevil's Avatar
 
Join Date: Nov 2004
Location: SAC,CA
Posts: 23,742
Posting Frequency
Images: 3
           
Electrical 101 Guess the Problem

Maybe we should have a contest type Forum for this stuff its fun to play around with, I even got my lady and son involved by showing them the Electrical Starter System Schematic only and described the problem.

As some of you know I have 3 Gen 1 Bikes now so future troubleshooting it may help with part swap for easy troubleshooting but not needed in this case…..take your best guess.

Symptom: Bike starts as soon as you turn the Ignition Key to ON Position but use to work for weeks before the failure and restore.

History: Bike is a 2004 Green is a wrecked Repo and restored by me maybe only 4-8k miles on the OD no rain damage…previous damage was all front end wiring at the headlight, starter clutch problems, and minor electrical problems for the headlight wiring at that fuse box. It also may have sat without being started for many years maybe 8yrs but that is just a guess.

Bloo

____________________________________________

Sent from My Computer via DSL mid to low service Firefox updated version, sometimes wireless sometimes Wire from the garage depending on connection speed.
bluedevil is offline  
Sponsored Links
Advertisement
 
post #2 of 4 Old 07-13-2014, 05:53 AM
WSB Rider
 
badassjake's Avatar
 
Join Date: Jun 2010
Location: Atlantic CANADA
Posts: 944
Posting Frequency
 
stuck/broken starter button and or pinched starter wire grounding out. That's a basic 2 wire loop.

2004 ZX10R-few mods here and there......
and even made more Evil by Woolich.
badassjake is offline  
post #3 of 4 Old 07-13-2014, 02:14 PM
Track Day Rider
 
Join Date: Nov 2013
Location: San Diego
Posts: 136
Posting Frequency
 
The starter circuit is a three stage relay and the 1st stage is easy to damage. The 1st stage is in the relay box and is coupled with a stator wire to turn the headlights on when the starter button is released. This is 3 relays in series, low power, medium power and then the high power that actually engages the starter. I chased this circuit a lot when my son's gen2 had the starter running intermittently after a stator and r/r failure. If the starter actuates while the engine is running and the battery is charging, too much current is drawn through the r/r regulator and it usually blows and could also burn the stator. The short story is: Replace the relay box with new. The used ones on ebay are a crapshoot because many are bad already. With 3 gen1s you could try a swap out with one of your other bikes to test before buying one. HTH
DaleC is offline  
Sponsored Links
Advertisement
 
post #4 of 4 Old 07-14-2014, 10:48 PM Thread Starter
Bloo Moderator
 
bluedevil's Avatar
 
Join Date: Nov 2004
Location: SAC,CA
Posts: 23,742
Posting Frequency
Images: 3
           
Quote:
Originally Posted by badassjake View Post
stuck/broken starter button and or pinched starter wire grounding out. That's a basic 2 wire loop.
Quote:
Originally Posted by DaleC View Post
The starter circuit is a three stage relay and the 1st stage is easy to damage. The 1st stage is in the relay box and is coupled with a stator wire to turn the headlights on when the starter button is released. This is 3 relays in series, low power, medium power and then the high power that actually engages the starter. I chased this circuit a lot when my son's gen2 had the starter running intermittently after a stator and r/r failure. If the starter actuates while the engine is running and the battery is charging, too much current is drawn through the r/r regulator and it usually blows and could also burn the stator. The short story is: Replace the relay box with new. The used ones on ebay are a crapshoot because many are bad already. With 3 gen1s you could try a swap out with one of your other bikes to test before buying one. HTH
Well been busy this weekend sorry for the late response but I think you both maybe right direction.....I think I unstuck the relay by hitting the starter button after the bike started then sprayed Lubricant in the left Ignition handle bar housing...either way it fixed the problem for now.... but still will investigate it may come back....the key here is there was enough current to open a relay but not enough to keep the Starter Motor operating after start-up....I will monitor and report back just wanted some to see if you send a problem to your dealer expect to have parts replaced first that don't need replacing. ....learn your bike and the Electronics first can save you alot of trouble.

Bloo

____________________________________________

Sent from My Computer via DSL mid to low service Firefox updated version, sometimes wireless sometimes Wire from the garage depending on connection speed.
bluedevil is offline  
Sponsored Links
Advertisement
 
Reply

Quick Reply
Message:
Options

Register Now



In order to be able to post messages on the Kawasaki ZX-10R.net forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:
OR

Log-in











Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
 
Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page
Display Modes
Linear Mode Linear Mode



Similar Threads
Thread Thread Starter Forum Replies Last Post
Gen 2: Electrical problem? RPowalish The ZX-10R 17 06-20-2011 06:23 PM
09 electrical problem ..I need help systems10sion General Motorcycle Discussions 4 05-02-2010 07:52 PM
04 electrical problem 11ute Performance and Tech 5 04-02-2009 11:07 AM
Electrical problem slav Performance and Tech 11 12-14-2008 11:32 AM
Serious Electrical Problem ajtmex Performance and Tech 11 12-25-2007 11:25 PM

Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome