Rebuilt my GZ. Now starter won't even click.

Steveoh · 07-27-2011, 02:03 PM

I recently bought a 2004 GZ for $800. It had sat in the weather for a year and I found it had been dumped. When the front brake pads fell off on the ride home, I decided to go through the whole bike.

The wiring harness was chopped up so I just tore it, the extra lights and wiring off and replaced that. I had to switch out the plug ins from the handle bar wiring, so I did this as I lengthen the wiring by 4" to fit the new handle bars. All tested out on the ohm meter. I also cleaned the carb, adjusted the valves,

The foot stand switch seems to test fine as does the new start/stop switches, . Fuses are all checked, battery is new, replaced the ignitor.
starter relay, coil, etc all seem to test ok, The ignitor didn't
Lights, horn, etc work.

I just have no spark and no juice to the starter. It is such a simple wiring system, I am just missing something.

geezer · 07-27-2011, 06:47 PM

before you over think things, apply power to the starter, does it spin? what about the starter solenoid? sounds like you handy with a volt meter so check and see if your getting voltage at the starter, if not go to the next point which should be the solenoid and keep going till you find your opening. so your not using the original bars, are they painted? im not sure if the handlebar controls are grounded to the bars. some bike do

Water Warrior 2 · 07-27-2011, 09:26 PM

You might want to double check the starter button. It is actually 2 switches in one. Push to start and it will disconnect the headlight while the starter whirls. Release and the starter disengages and the headlight comes back on. You might have a bad connection from the long overdue cleaning up.

Hmm, hey guys and gals. Did I just describe that right or am I thinking of another Suzuki ?? M-50 maybe.... :??:

5th_bike · 07-27-2011, 09:37 PM

Quote:

Originally Posted by Water Warrior

You might want to double check the starter button. It is actually 2 switches in one. Push to start and it will disconnect the headlight while the starter whirls. Release and the starter disengages and the headlight comes back on. You might have a bad connection from the long overdue cleaning up.

Hmm, hey guys and gals. Did I just describe that right or am I thinking of another Suzuki ?? M-50 maybe.... :??:

The wiring diagram only shows one contact, for the ignition, at the starter button. Must be another bike you're talking about.

Water Warrior 2 · 07-27-2011, 09:48 PM

Yeah, haven't had the GZ for a couple years and wasn't totally sure anymore. Both other bikes work as I mentioned and can be a headache if the switch gets all corroded by weather and such.

Steveoh · 07-29-2011, 10:01 PM

The headlight stays on when I start (try) the GZ. On the 800 Intruder, the headlight does disconnect while starting.

I am beginning to believe that the problem is the in the wiring harness I installed. I'm just waiting for the garage to cool off a bit before testing wires.

KrazeeMyke · 07-30-2011, 04:11 AM

Quote:

Originally Posted by Steveoh

I just have no spark and no juice to the starter. It is such a simple wiring system, I am just missing something.

Maybe silly question, but. ....Are you engaging the clutch? There is a safety switch. Bike wont engage starter unless in Neutral and clutch engaged/applied.

geezer · 07-30-2011, 09:58 AM

might be a good idea to ride two up with someone more experienced so he or hopefully she can teach you. this is getting crazy, yall need to get the basics down or your gonna get hurt eventually

blaine · 07-30-2011, 10:04 AM

Quote:

Originally Posted by geezer

might be a good idea to ride two up with someone more experienced so he or hopefully she can teach you. this is getting crazy, yall need to get the basics down or your gonna get hurt eventually

I think you meant this for here.
viewtopic.php?f=4&t=4620&p=52597#p52597

:cool:

Steveoh · 07-30-2011, 10:53 AM

Geezer??? I wish that I had known that I should not test a motorcycle battery like a 9V battery, with my tongue, it hurts.

Anyway, yes, the bike is in neutral and the clutch lever is zipped locked closed. I am still testing the wiring harness since this is the only electrical item that I replaced before the bike would not start.

07-27-2011, 02:03 PM	#1
Steveoh Junior Member Join Date: Apr 2011 Location: San Carlos Park, FL Posts: 10	Rebuilt my GZ. Now starter won't even click. I recently bought a 2004 GZ for $800. It had sat in the weather for a year and I found it had been dumped. When the front brake pads fell off on the ride home, I decided to go through the whole bike. The wiring harness was chopped up so I just tore it, the extra lights and wiring off and replaced that. I had to switch out the plug ins from the handle bar wiring, so I did this as I lengthen the wiring by 4" to fit the new handle bars. All tested out on the ohm meter. I also cleaned the carb, adjusted the valves, The foot stand switch seems to test fine as does the new start/stop switches, . Fuses are all checked, battery is new, replaced the ignitor. starter relay, coil, etc all seem to test ok, The ignitor didn't Lights, horn, etc work. I just have no spark and no juice to the starter. It is such a simple wiring system, I am just missing something. Login or Register to Remove Ads
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07-27-2011, 06:47 PM	#2
geezer Senior Member Join Date: Mar 2011 Location: dahlonega GA Posts: 563	Re: Rebuilt my GZ. Now starter won't even click. before you over think things, apply power to the starter, does it spin? what about the starter solenoid? sounds like you handy with a volt meter so check and see if your getting voltage at the starter, if not go to the next point which should be the solenoid and keep going till you find your opening. so your not using the original bars, are they painted? im not sure if the handlebar controls are grounded to the bars. some bike do __________________ 99 gz 250 and a currently dismantled fzr 1000
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07-27-2011, 09:26 PM	#3
Water Warrior 2 Senior Member Join Date: Dec 2006 Location: Squamish B.C Canada Posts: 11,409	Re: Rebuilt my GZ. Now starter won't even click. You might want to double check the starter button. It is actually 2 switches in one. Push to start and it will disconnect the headlight while the starter whirls. Release and the starter disengages and the headlight comes back on. You might have a bad connection from the long overdue cleaning up. Hmm, hey guys and gals. Did I just describe that right or am I thinking of another Suzuki ?? M-50 maybe.... :??: Login or Register to Remove Ads
	0

07-27-2011, 09:48 PM	#5
Water Warrior 2 Senior Member Join Date: Dec 2006 Location: Squamish B.C Canada Posts: 11,409	Re: Rebuilt my GZ. Now starter won't even click. Yeah, haven't had the GZ for a couple years and wasn't totally sure anymore. Both other bikes work as I mentioned and can be a headache if the switch gets all corroded by weather and such. Login or Register to Remove Ads
	0

07-29-2011, 10:01 PM	#6
Steveoh Junior Member Join Date: Apr 2011 Location: San Carlos Park, FL Posts: 10	Re: Rebuilt my GZ. Now starter won't even click. The headlight stays on when I start (try) the GZ. On the 800 Intruder, the headlight does disconnect while starting. I am beginning to believe that the problem is the in the wiring harness I installed. I'm just waiting for the garage to cool off a bit before testing wires.
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07-30-2011, 09:58 AM	#8
geezer Senior Member Join Date: Mar 2011 Location: dahlonega GA Posts: 563	Re: Rebuilt my GZ. Now starter won't even click. might be a good idea to ride two up with someone more experienced so he or hopefully she can teach you. this is getting crazy, yall need to get the basics down or your gonna get hurt eventually __________________ 99 gz 250 and a currently dismantled fzr 1000
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07-30-2011, 10:53 AM	#10
Steveoh Junior Member Join Date: Apr 2011 Location: San Carlos Park, FL Posts: 10	Re: Rebuilt my GZ. Now starter won't even click. Geezer??? I wish that I had known that I should not test a motorcycle battery like a 9V battery, with my tongue, it hurts. Anyway, yes, the bike is in neutral and the clutch lever is zipped locked closed. I am still testing the wiring harness since this is the only electrical item that I replaced before the bike would not start.
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