Starter Motor Relay and the Starter

Hey Guys, Just bought an '82 305crs that has been sitting for 10 years. I wanted to see if it would crank before I did anything else to it. I put a charged battery on it, but the starter wouldn't turn. The horn and lights were working though. I was getting 12 volts at the starter motor relay. I had 12 volts at the key ignition. I am getting 10 volts at the run switch/ push button starter. Back at the relay I'm getting not quite 10 volts from the push button starter. I have started trucks and tractors before by jumping over the starter motor relay but nothing happened with the bike (don't know if its possible or not but thought I would try). Is this a bad relay or is some else going on here? Thanks!

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. If the cables feel “Crunchy” when flexed, they may have corrosion inside the insulation, requiring replacement.

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. A website for starter motors is:

A. www.psep.biz/store/mitsuba_starter_motors_page_2.htm

B. www.nationsautoelectric.com/Kawasaki.html

C. www.whitedogbikes.com/cat--Kawasaki-Star...-Starter-Motors.html

D. www.ricksmotorsportelectrics.com/starters.php

E. www.dbelectrical.com/

F. www.stockers.com/index .

G http://.www.nationsautoelectric.com/Kawasaki.html

H http:// www.dbelectrical.com/


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.

Did you pull in the clutch lever? Ed

Thanks Guys... i had tried using the screw driver trick on the solenoid before. Just tried it again while holding in on the clutch and still nothing... Will have to check the starter next... I pull it off and see what kind of shape its in. Thanks for the speedy replies I appreciate it!

Is 12V not too low to start the bike? Can you charge the battery to at least 13.5V & then try