1991 Zephyr 750 No Start Issue

Hello All, I have an issue with my 1991 Kawasaki Zephyr 750. I replaced the seals behind the front sprocket & the shifter to fix a bad oil leak. I also replaced the clutch friction plates that were worn out. After getting it all back together I went to test ride & now i turn the key on all the lights come on until I push the starter button, the starter solenoid clicks & all lights go out like blowing a fuse but they are all fine. Anywhere from 5 to 30 seconds & all lights come back on until you hit the button & again, click & dead again. I replaced the solenoid with a known good one, same thing happens. I don't recall messing with anything wiring wise under either engine covers, could I have missed a ground somewhere? Thanks!
 

Does sound like a "ground" issue. Connect the black lead from a voltmeter to battery negative then the red lead to the body of the starter motor, ignition on, operate the starter button - any more than 0.3v shows an engine ground issue

.No offense but...No mention of battery voltage, and/or condition, ........and if in doubt,  I'd try jump starting it from another 12VDC source.,....preferably with bike battery disconnected.  

I'm betting you probably pinched a wire somewhere and at some point during the reassembling process.  Take a close look at those pieces you took off, for any wire issues.

Thank you, this is what I was looking for, I can pull the engine covers off again if I have to, but rather not. I really don't recall seeing any grounds when I took the covers off but it was a month or so ago.  It is unfortunate, pretty much all shops in the Seattle area are gone, USPS took almost 2 weeks to get my clutch plates to me.

Wookie58 wrote:

Does sound like a "ground" issue. Connect the black lead from a voltmeter to battery negative then the red lead to the body of the starter motor, ignition on, operate the starter button - any more than 0.3v shows an engine ground issue

Sorry, I should have mentioned the battery was fully charged & is a couple of years old.  The Zephyr doesn't get ridden as much as my KZ650 but it gets a turn on the battery tender at least once a week, but good idea, I can use the KZ battery for diagnostic work.

hugo wrote:

.No offense but...No mention of battery voltage, and/or condition, ........and if in doubt,  I'd try jump starting it from another 12VDC source.,....preferably with bike battery disconnected.  

already mentioned. but make sure the battery is good. do a load test. 

Hello, is it an old agm (glass mat) battery, what you described is what they do when they fail, lights on all looks good then hit starter and nothing, just replaced one in z1, noco 2x2 would not stop flashing, suspected bad regulator was over 15v, configured tne harness and replaced with a sh775, (thanks Mr Nessism), at work we had plenty of agm’s in fire alarm systems, failed the same way, full charge, then trip out like a circuit breaker,  bad cell,  

Update: Took the battery to a friend's shop this morning & tested it, 12.75 fully charged & load tested bad. Lesson learned, start with the basics, I didn't suspect the battery since it's the same as the nearly 10 year old Bikemaster AGM in my KZ, less than 2 years old & been maintained exactly the same. Thanks for the suggestions, at least now I know all of my ground wires are good & electrical connections are clean.

It's often the simple things that catch us out. On the upside you now know how to test a "ground" as the process is the same for the ground to any consumer - the only time you will see more than 0.3v on the ground side of a consumer is if there is another resistance (bad connection) between there and the battery neg post