Starter doesn't work all of a sudden

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18 May 2020 15:00 #826023 by dpivas7
Starter doesn't work all of a sudden was created by dpivas7
I am working on a 1984 GPz550 and I had it running just last week, but the air filters needed replacing so I ordered some new ones.

They arrived today and I replaced the filters without even taking the carb off so the only thing I touched were the old filters. I went to start the bike once the filters were on and the starter turned over a few times but then nothing. When I click the ignition, the starter doesn't even turn over anymore. The battery has juice (12.6V before turning key on, 12.3V after) and there is full voltage at the starter relay.

I've had this issue before on other bikes but have never figured it out. All the cables and wires look good, I couldn't find anything amiss.

Could it be the starter relay needs replacing? I struggle with diagnosing electrical problems so any help is appreciated!

Current: '19 Harley Roadster, '72 XLCH, '84 GPz 550
Past: '84 GPz 550, '82 KZ750 LTD, '71 XLCH

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18 May 2020 15:11 - 18 May 2020 15:11 #826024 by TexasKZ
Replied by TexasKZ on topic Starter doesn't work all of a sudden
How many volts does the battery show when you push the starter button?

1982 KZ1000 LTD parts donor
1981 KZ1000 LTD awaiting resurrection
2000 ZRX1100 not ridden enough
Last edit: 18 May 2020 15:11 by TexasKZ.

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18 May 2020 15:17 #826025 by dpivas7
Replied by dpivas7 on topic Starter doesn't work all of a sudden
12.3V - same as when I turn the key.

Current: '19 Harley Roadster, '72 XLCH, '84 GPz 550
Past: '84 GPz 550, '82 KZ750 LTD, '71 XLCH

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18 May 2020 17:47 #826047 by TexasKZ
Replied by TexasKZ on topic Starter doesn't work all of a sudden
It should drop a bit, so it seems that something is disconnected. It could be something inside the starter button housing. Solder gets brittle as it ages and can come apart. The switch contact could be burned or broken. Could be a loose connection anywhere in the starter button circuit that just finally decided to separate.
Taking careful readings with your multimeter at several places in the circuit should help you narrow down the culprit. Is power getting to the solenoid (small wires)? To the starter button? In and out of the ignition switch?

1982 KZ1000 LTD parts donor
1981 KZ1000 LTD awaiting resurrection
2000 ZRX1100 not ridden enough

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