Question about kawasaki Motorcycles

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1991 Kawasaki ZR550 Zephyr relay clicks will not turn over

My bike won't turn over. Battery is charged, indicators, stop light and horn work. When I hit the start button, the bike just clicks. Noise coming from the junction box. Any ideas on possible problems? @

Posted by Anonymous on

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  • kawasaki Master
  • 48,076 Answers

Hi, Anonymous before testing any electrical component in the Starter Circuit it is "IMPERATIVE" that you have a fully charged battery of 12.5 volts or more and be able to pass a proper "LOAD" test if necessary, you may have a preliminary reading of 12.5 volts or more but little or zero amperage, the battery is faulty and must be replaced. AGM type batteries fall into this scenario more so than lead-acid batteries. Depending on battery voltage starter relays and starter solenoids can make the same noise when you hit the starter button. You can easily determine which one is at fault by two simple tests:
STARTER RELAY- place your thumb and index finger on the starter relay and press the starter button, if you feel the click then the relay is faulty and needs to be replaced.
STARTER SOLENOID- bridge the positive and negative poles of the solenoid with a small screwdriver if you get a loud clunk then the solenoid needs to be rebuilt or replaced as necessary. If the engine turns over then replace the starter relay.
A motorcycle starter relay is an electronic mechanical switch that has a small coil winding around a piece of metal that requires low amperage and thin wires to be activated. When you turn on your ignition switch power 12 volts is sent to the relay coil which in turn becomes a magnetic contact point that pulls a spring-loaded contact point to itself completing an electrical circuit that allows more amperage necessary to be accessed by the starter solenoid which in turn acts in the same way as the relay but on a larger scale with its stronger heavier contacts making available the necessary amperage to turn the starter motor. If your battery has low voltage it, in turn, makes the magnetic contact point weak in trying to pull its counterpart to make a connection. These relays are usually encased in a plastic housing that is sealed depending on the quality of the product. When activated they will produce a small amount of heat to their metal components which in turn can create the perfect environment for condensation to form depending on weather conditions and how careless you may be with a water hose or sprayer while washing your bike. After a period of time, several months to several years depending on the circumstances this condensation is the starter button for electrolysis and the slow build-up of corrosion which ends by preventing the magnetic contacts in making a solid connection and alerts you to this situation with the customary greeting "CLICK or BUZZ" if you get a single loud "CLUNK" then the starter solenoid is at fault and needs to be rebuilt or replaced as necessary. The relay is inexpensive and needs to be replaced however in a pinch they can be forcibly opened cleaned and resealed with silicone. In a nutshell, motorcycle starter relays take in low amperage and send out higher amperage when activated and for curious minds, the voltage remains constant at whatever your battery reads at the time.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
Kawasaki ZR 550 Zephyr starter relay starter relay starter solenoid switch...
junction box click Kawasaki Vulcan 750 Forum Kawasaki VN750 Forums
Kawasaki ZR550 Zephyr 1990 1997 Service Repair Manual PDF Download Manuals... $15
OEM Parts for Kawasaki
http://mybikemanuals.com/kawasaki

Posted on May 05, 2018

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Posted on Jan 02, 2017

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onyeredson
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SOURCE: push starter button and no start

Hello,
Evansville! Nice part of the World.
Bud's Harley Shop still there?
O.k. daft thing is the off run switch on the handlebars turned to off?
Failing this will the bike start and run off bumping (Push start).
If it does take a look at the battery (Maybe Dead cell/s) or Starter solenoid wire/fuse.
Solenoid is located near the battery it is the cylindrical item with the main pos+ wire from battery going to it.
Good Luck! could do with a new Bud's Harley 'T' shirt as mines worn out.
Paul 'W'
Onyer~EDson(:0 {#><U.K.
Oh! please remember to politely rate my effort!

Posted on Jan 21, 2009

  • 2 Answers

SOURCE: Non Starting of Triumph Trophy 3

Try wiggling the ignition key or perhaps turn off & on whilst holding the starter button in. Might be a dodgy ignition switch.

Posted on May 15, 2009

  • 5 Answers

SOURCE: where is fuse box for indicators, horn and ignition lights

They are in the right side cover by the batt.

Posted on Jun 17, 2009

  • 2 Answers

SOURCE: Press starter button then a crackling, clicking sound in Relays

You might first try and (jump) the starter at the starters bendex. To do this you could use a jumper wire or a screwdriver if you know what you are doing... (jump or connect together) the one (thin) red wire leading to the back of the starters bendex and the one (thick) cable also leading to the back of the starters bendex...being careful not to "ground" your jump wire or screwdriver to the bikes frame!!!... "Make sure you are in neutral"!!! ...Turn the ignition to the on position. You may have to engauge the start button at the same time you jump these leads. If your bike still clicks instead of turns over/starts.. Either the battery is not up to snuff...try boost starting from off you car or truck to determine this if you do not have the proper battery test equipment: (or) there is a loose or corroded connection. It is possible the connection at the starter button also is crusty. To clean your connections well, "You must first disconnect the negative terminal at the battery"!!!... Clean all the contacts/connections the same way using an electric contact cleaning spray (that evaporates) and a med-soft bristle brass wire brush. You really should start from the battery to the starter and also the starter button if accessible. A light wipe over from a clean cloth sprayed sparingly w/a light oil or silicon afterwards on all cleaned areas should keep them being that way again till next year if your bike is ridden in fowl weather often and/or left out in the elements. I find it hard to believe that all the relays went out simultaniously!!!...It is almost impossible. Guzzi-Guy

Posted on Jul 17, 2009

bozcro
  • 867 Answers

SOURCE: 92 FXR bike will not start or even turn over

that clicking sound is the starter solenoid. check all large cables for corrosion and tightness. as for the signal lights, neutral and horn, i think a wire is grounding , thus causing the problem with the bike not starting also. check at ignition switch and at handle controls for a loose wire that may be touching the handlebar. basically inspect all the wiring on the bike

Posted on Aug 08, 2009

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