starter and starter relay

I recently, 3 weeks ago, bought a basket case. My first bike build. A 1983 Kawasaki KZ 550, not an LTD. So far I love it. Lots of problems to overcome and lots of learning for someone who knows nothing about bikes. I've gotten a lot done but now I'm onto the wiring and I have two wiring harnesses. Almost everything connects, except one red wire. Anyway, I thought my starter relay (selenoid)wasn't working because it wouldn't click, now it does. I touched the black wire on the relay (the one that goes to the start button) to the post connnected to the battery (the positive post). I could not resist hearing the bike try to start. The starter turned a couple of times but now it doesn't. My bike was in gear but the chain isn't on, so it wasn't trying to turn the wheel. But did I possibly burn the starter out? Why won't the starter turn now when it did before? All I get now is a spark at the battery terminal and the lights on the instruments go out. I then have to take the cables off the battery and put them back on to get the starter relay to click again. Anyway that was a long story but if anyone has any ideas as to what I should try next please let me know.

I havn't been able to, but if you can find a wiring diagram somewhere, it will likely assist considerably.

The starter solenoid needs a ground, and a positive activation connection. Seems you've made the connection manually, but in the process you probly have blown a fuse, or perhaps shorted something else out.

Start with the easiest stuff. Pull the solenoid off and try it with a multimeter and another battery. Pull the starter out and connect it to a batt, and see if it turns over.

GL!

Starter Solenoid/Motor Checkout Procedure

Some simple steps to determine what is working and what's not:

1.Fully charge and test the battery(most bike shops can load test the battery, and then use a floating ball hydrometer to check specific gravity in the charged cells).

2.Clean all battery terminals of corrosion.

3.Tighten all starting related connections(Positive RED(+) battery terminal, Negative BLACK(-)terminal) and from the terminal to the engine case. All connections must be clean and tight.

4.Clean the cable from the starter solenoid to the starter motor.

5.Clean and check the "bullet connectors" going to the coil side of the starter solenoid.

6.Try again to start the bike, keep in mind some Kawasaki’s have a clutch interlock to prevent cranking the engine while it’s in gear, so the clutch lever must be squeezed.

7.If no luck, go to step #8

8.Wearing eye protection, bridge with pliers or a screwdriver the two heavy duty(large)terminals on the solenoid. If the bike cranks, your solenoid may be bad.

9. If the starter won’t turn over, one of several things has happened; The starter motor has seized due to brushes binding up, lack of lubrication in the bushings of the motor, the battery is weak , the engine has seized or it could be a combination of any of the above. Some websites for starter motor rebuild kits are:

A. www.mawonline.com/newsite/rick_s_motorsp...-starter_brushes.htm

B. www.cyclewareables.com/pages/street_star...kits/startmtrkit.htm (not sure if the website is still viable)


10.The dealer may want $$$ for a new solenoid, but take your old one along and visit the nearest riding lawn mower shop. They have solenoids for about $15 that with a little work will fit. Be aware that the new solenoid from the lawn mower shop may require a ground wire for it to work.

11. I’d recommend upgrading from the existing battery cables to at least 6 gauge welding cables.
They are available in two colors(RED and BLACK) have more flexibility due to being constructed with finer conductors, and will fit in tighter areas.

12. The welding cable is sold by the foot, so take careful measurements or bring your old cables along. Most battery shops might be able to supply the cable too, so call to find out. The battery shop should be able to crimp/swage on the end of the welding cable the terminal ends or lugs using either a dedicated crimping machine or a tool that looks like a bolt cutter that has special dies to terminate the cable.

Thanks a lot guys. Can't wait to get home from work tonight to start checking things out.
New battery and fully charged, check.
Battery terminals clean, check.
Connections tight, I was just laying the positive and negative cables on their terminals cause it's a pain hooking them up and unhooking them all the time.
Clutch interlock bypassed, don't need it, when the bike is fully built and I go to ride I know to start it in neutral.
I did step 8 and the starter did not crank. The solenoid is working, I hear it click when I push the start button.
Thanks again guys I still have a few things to try out. I'll be back with questions and maybe answers tonight.

PM Loudvhx.... He has a lot of knowledge on the 550 series... Plus electrical is his expertise...

Thanks again. It looks like it is going to storm in a few minutes and the only place I have to work on the bike is in the back yard so I may not get anything done tonight. I did have a guy at work look at my second starter and he said it looks like new on the inside, I shouldn't have any trouble with it. Things are looking good. Still happy and still building.

Ohh hell yahh!! Push the start button and the solenoid clicks and the starter turns. The first noise this basket case has made. I put the first starter back on after a guy I know looked at it and said it's like brand new, there's nothing wrong with it. Connected the starter button back up and connected the battery cables on fully. Pushed the button and made noise. I think the problem was mainly poor connections. Thanks for all your help and advice guys.

Glad we could help out. If any more problems are found, don't be afraid to ask......

I got my bike running. It's alive. I didn't run it for very long, not even a minute. I believe it has a rebuilt engine and I want to work it in properly. I need an air filter, it's on its way my mail. And I need to get the exhaust pipes attatched properly. I have a few broken bolts which are to hold on the exhaust. I need to clean up the wiring. I want to eliminate everything that I can so it isn't so clutered. Anyway, thanks and I will post pics as soon as I can find where my wife put the camera.