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Followup To
Question -
I have a 1994 Kawasaki Vulcan 750. I have an intermittent problem with starting. When I go to start the bike, I turn on the key all gauge lights and warning light light up as normal. I then press the start button and nothing happens, the lights don't dim nothing. When this happens I turn the key off and on flick the engine stop a couple of times and put it in and out of neutral and press the start button. After doing this a number of times the bike starts as though there was no problem what so ever. I have a newer battery that keeps a good charge. This happens when the engine is hot or cold. I have checked the battery connections they are fine. I have checked the connectors in the fuse/circut relay block they are ok. Other than this problem this bike runs very well. As I said this problem is very intermittent, has happened approximately 4 times in last 5 months.
Thanks Todd
Answer -
Hi Todd,
Check starter button electrical contacts for corrosion. I've found spider webs and dead insects in these button contacts and causing the problem (non-conductors).
Bench test starter solenoid, should click and jump when 12 vdc is applied to the small lead. The body is ground.
Check all safety switches: clutch, engine on/off sw, neutral sw, sidestand sw, for proper operation.
Check the starter motor carbon brushes for wear. Measure the length of each brush. Replace if necessary. Clean carbon powder from starter motor assy. Use electrical contact cleaner spray.
I recommend the Service Manual for assistance. It will pay for itself with the first repair.
Respectfully,
Mark Shively
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Mark
Its funny that you mention the neutral sw and the side stand sw, because those are the only two things on this bike that don't work. At first I thought that they didn't work due to a fuse or something like that, but I checked all of the fuses and that was not the problem. Is there an electrical component that controls the side stand sw the neutral sw, and the starter sw?
Thank you very much
Todd
AnswerI think you've found the problem.
You can bypass the switches to rule them out of the process of diagnosis. Remove them from the circuit, or jump the lead to ground.
See the service manual for testing procedures and specs on these parts.
Mark
