Motorcycle Repair: Kawasaki battery replacement, starter solenoid, alligator clip

Question
I was having battery problems with my 2002 Vulcan all last year; I got a new battery and was having trouble fitting it back in, while trying every possible sequence it finally fit! I realized I had dropped it in backwards. I noticed it right away and turned it right side, hooked it back up, and the bike is dead. No power, nothing. The battery seems to have juice, the fuses are fine. Any thing else that, would effect that so dramatically. Any help would be great.

Thanks!  

Answer
Hi Janet,

Test the battery and verify it fully charged and in good condition. Charge or replace the battery accodingly.

If battery is okay, trace voltage with a 12 volt tester until you find the source of the problem.

I suspect a loose or disconnected electrical connector. It may be other, though.

Once you get the battery/power problem sorted out, perform an output test to check the charging system.

I return tech files by email. There was no email address with your question as requested.

Respectfully,
Mark Shively



(sample Tech File)

Using a 12 Volt Tester
By Mark Shively

Use a 12 volt tester and trace voltage from battery, to main fuse, fuse box, and through related circuits. A 12 volt tester looks like an ice pick with long lead/wire and an alligator clip at the end of the lead.

When the ignition key is turned to the "On" position, voltage flows to the fuse box, ignition switch, starter solenoid, and starter button.

When the starter button is depressed, voltage flows to the starter solenoid. It becomes an electro-magnet and moves the internal electrical contact. High current flows to the starter motor for starting the engine. High current and starter motor gear reduction is required to overcome cylinder compression.

Safety switches such as the side stand sw, engine on/off sw, clutch sw, all interrupt the ground circuit. If any of these switches become defective, the engine will not crank/rotate/turn-over.

Check continuity of ignition pick-up coil (aka: pulse or pulsar coil). If this is defective, coils get no signal.

If the CDI is defective, coils and other components may not receive a signal. Test with a known good CDI.