ZXR400H "Electrically Dead"
Posted: Mon Apr 11, 2016 11:11 am
Hi guys,
Looking for some ideas or input from anyone that might know more than me. What tends to be common problems, etc:
Bike History:
Recently bought a ZXR400H '89 (registered in '90) to run around whist I rebuilt the brakes on my GSXR (which subsequently turned into a nut & bolt rebuild). Great fun, I love it.
It was a good deal but a bit of a shitter - Lovely new respray Kwak green and gold fleck paint job obviously hiding a similarly colourful past! But there were receipts for an engine rebuild and mechanically it hasn't missed a beat. The wiring is a rats nest though, connectors that would be more at home in a dry wall and all kinds of things plumbed in I don't even know what they do.
Problem Description:
Anyway it was actually running great to my suprise until it took a dive off the side stand in the gales a few weeks ago, landing on its left hand side (with an impact that displaced the starter relay solenoid). I put another 200 miles on it just fine but then started having trouble - One morning I turned the key and no dash lights, no head lights, no click on the relay soleniod, no horn. I jiggled the key, off to on to off again and the dash came up & it started off the button.
I rode to my destination but as soon as I rolled to a stop it cut out, the dash died & it wouldn't start again. So I did a day's work and came back and when I stuck the key in the dash did light up but there wasn't enough power in the battery to get it to turn over. After a while I got it bump started but whilst running it was odd because the Running lights worked & the Full Beam worked, but the main headlights did not?! Any how after that journey I parked it, covered it and next time I went to it, again - no dash lights.
Remedial work so far:
1.Obvious first port of call was the battery - it isn't in great shape and a replacement is on its way, but it went on a deep cycle & should have enough charge to at least power the dash lights.
2.Fuses - all checked, no blown fuses
3.Starter Relay - I found the connector block (that holds the main fuse & pins) pretty bust up (any idea where I can get a new one?) and the white cable had been torn from the block and there was significant white corrosion here. So I thought BANG, thats got to be it, nice easy fix! So I recrimped and soldered a new spade connector and gave it all a good clean. The connector block is ugly but I've tested that there is a solid connection on all pins. But still to my great annoyance there is no life at all on the dash when ignition set to RUN or running lights when ignition set to PARK.
4.Kick it
5.Chain smoke cigarettes and swear at it.
I guess my next logical step is the ignition switch & continuity on the white cable that I THINK runs from the + terminal of the Main fuse to the ignition switch. Trouble is the only wiring diagram I can find is for a different, later model - I hope it hasn't changed too much.
If I get continuity there whats the next place to go? I guess it could be a bad ground too? but where is the ground?
Has anyone got any other ideas? Are there any other components that might have burnt out that could cause it.
The loom is such a bloody mess I'm not relishing the idea of tracing it all down (I'm not great with electrics) or paying for the hours it would take if I took it to the shop. I'm finding myself a bit confused because it seems like 2 problems. Firstly the initially intermittent problem of no electrical power at all, secondly the apparent low cranking amps, though I guess whatever caused 1 probably interferes with the charging system too...
Looking for some ideas or input from anyone that might know more than me. What tends to be common problems, etc:
Bike History:
Recently bought a ZXR400H '89 (registered in '90) to run around whist I rebuilt the brakes on my GSXR (which subsequently turned into a nut & bolt rebuild). Great fun, I love it.
It was a good deal but a bit of a shitter - Lovely new respray Kwak green and gold fleck paint job obviously hiding a similarly colourful past! But there were receipts for an engine rebuild and mechanically it hasn't missed a beat. The wiring is a rats nest though, connectors that would be more at home in a dry wall and all kinds of things plumbed in I don't even know what they do.
Problem Description:
Anyway it was actually running great to my suprise until it took a dive off the side stand in the gales a few weeks ago, landing on its left hand side (with an impact that displaced the starter relay solenoid). I put another 200 miles on it just fine but then started having trouble - One morning I turned the key and no dash lights, no head lights, no click on the relay soleniod, no horn. I jiggled the key, off to on to off again and the dash came up & it started off the button.
I rode to my destination but as soon as I rolled to a stop it cut out, the dash died & it wouldn't start again. So I did a day's work and came back and when I stuck the key in the dash did light up but there wasn't enough power in the battery to get it to turn over. After a while I got it bump started but whilst running it was odd because the Running lights worked & the Full Beam worked, but the main headlights did not?! Any how after that journey I parked it, covered it and next time I went to it, again - no dash lights.
Remedial work so far:
1.Obvious first port of call was the battery - it isn't in great shape and a replacement is on its way, but it went on a deep cycle & should have enough charge to at least power the dash lights.
2.Fuses - all checked, no blown fuses
3.Starter Relay - I found the connector block (that holds the main fuse & pins) pretty bust up (any idea where I can get a new one?) and the white cable had been torn from the block and there was significant white corrosion here. So I thought BANG, thats got to be it, nice easy fix! So I recrimped and soldered a new spade connector and gave it all a good clean. The connector block is ugly but I've tested that there is a solid connection on all pins. But still to my great annoyance there is no life at all on the dash when ignition set to RUN or running lights when ignition set to PARK.
4.Kick it
5.Chain smoke cigarettes and swear at it.
I guess my next logical step is the ignition switch & continuity on the white cable that I THINK runs from the + terminal of the Main fuse to the ignition switch. Trouble is the only wiring diagram I can find is for a different, later model - I hope it hasn't changed too much.
If I get continuity there whats the next place to go? I guess it could be a bad ground too? but where is the ground?
Has anyone got any other ideas? Are there any other components that might have burnt out that could cause it.
The loom is such a bloody mess I'm not relishing the idea of tracing it all down (I'm not great with electrics) or paying for the hours it would take if I took it to the shop. I'm finding myself a bit confused because it seems like 2 problems. Firstly the initially intermittent problem of no electrical power at all, secondly the apparent low cranking amps, though I guess whatever caused 1 probably interferes with the charging system too...