ZXR750 L2 Clicking sound from junction box

[ZXR750L2]

Hi all, I am currently slowly doing up my 1994 ZXR750L2. Over the past month I figured the battery was going because when I would hit the start button the headlights would not come on and it would take a few hits of the start button before the lights would come on, and then the starter motor would engage (also found that when the clutch was pulled in it tended to want to start). I bought a new battery and it has not solved the problem. The other day it did the same, however, there were no headlights on and when I hit the start button all I got was a clicking sound from the junction box. I tested the battery - it's all good. With the ignition on, I tested the starter soleniod (left side of bike), I had power to it, so I shorted the 2 points on the starter solenoid and the starter motor turned over no problems. I figure that means that my junction box has crapped itself thus the clicking sound!! Anyone else have any theories or experienced anything like this? Would appreciate any advice and ideas where the best place to source parts. Cheers.

[razza01]

Hi mate, take the seat off and next time it clicks tap the starter relay to see if that makes it crank.

[Gav]

Maybe a bad contact on ya starter button on the switch block.

[Gosling1]

starter relay is fuxored - just get a new one, that will sort the problem out.

[Gav]

starter relay is fuxored - just get a new one, that will sort the problem out.

Yeah, my zxr had the same problem,and I changed the starter relay with a new one from kawasaki.
It was only after the starter button decided to part company with the rest of the bike,and replacing the switch block
that the "ticking/clacking /annoying sound vanished.
It has'nt done it since.
Hope that helps

[Kwak addict]

I have had 2 starter solenoids fail on ZXR Ls so I'd try that before replacing the starter relay.

[ZXR750L2]

Righto, I have ordered a starter solenoid and a new juction box (for both in working order $70) Just waiting for delivery. Pick up my new fairing graphics tomoz so I can get ready to spray the fairings and the bike will look like new again - that is if the soleniod/junction box do the job! Thanks for the suggestions and I will advise of the outcome at the weekend.

[Gosling1]

I have had 2 starter solenoids fail on ZXR Ls so I'd try that before replacing the starter relay.

He did mate - shorted the contacts and the bike started straight away. I think the solenoid is fine - it will be the starter relay.

if the bike had not started.....then yeh, solenoid would have been first choice.

[ZXR750L2]

Well I put in the new junction box and starter soleniod and guess what.... click click click click. I have no head lights but the dash is lit up like a christmas tree (battery is fully charged), figure it might be the starter switchblock. I have a spare one so will whack that on this weekend - hopefully that will solve the issue!! Otherwise I have run out of ideas!! Maybe a bad earth??

[ZXR750L2]

Faaaark!!! I have replaced the starter switchblock, replaced the junction box, replaced the starter solenoid and still get the bloody clicking sound with no start!! I short the starter solenoid and the starter turns no problems. It seems that when I pull the clutch in the headlights will come on, but when I hit the start button the headlights go out (but the dash is still lit up like a christmas tree) and the old gal won't turn over. it's not the battery as it is new. Are there any other switches that may impact on starting?

[Maddog]

Could it be the switch under the clutch lever for the stand over ride ?...Did this model have one ?
If so unplug it and loop the plug on the wiring harness..Maybe same for the stand.



Hope you get it sorted soon.

[Jonno]

My old ZX9R B series use to do this randomly and i have NFI what was causing it or if it is still doing it, it is now Marksess's problem


I suspect its a dirty switch contact or wiring issue as I swapped everything else out.

[marksesh]

My old ZX9R B series use to do this randomly and i have NFI what was causing it or if it is still doing it, it is now Marksess's problem


I suspect its a dirty switch contact or wiring issue as I swapped everything else out.

Still doing it!!!

[Kwak addict]

He did mate - shorted the contacts and the bike started straight away. I think the solenoid is fine - it will be the starter relay.

if the bike had not started.....then yeh, solenoid would have been first choice.

The problem with my 2 ZXRs was that you could have switched power to the solenoid inputs (checked with a testlight) but the loss of connection actually occurs within the body of the solenoid so the starter relay will still click because it's doing its job of transmitting power down the line but the electricity stops when it gets to the solenoid.
I liken the action of the standard ZXR L starter solenoids vs the later plastic jobs to the difference between a thermal & an electronic indicator flasher can, the ZXR ones have a slight delay when pressing the starter button - like they're just waking up - they seem to need to build up some heat before they switch whereas the later plastic ones are a strong & sharp instant connection. (this delayed action of the originals may be due to the internal contacts being worn/corroded & on the way out - I've never tried a brand new one.)
I found a later model Kwaka solenoid (there's no part No. on it sorry) that is made of square plastic rather than the standard round metal units on the Ls, it required the pink plug to be turned 180 deg. & physically modified to fit in but it works much better than the stocker.
A working starter will always turn when the solenoid poles are bridged, it's the same as putting the + lead straight from the battery to the starter.
As others have said, the contacts for the starter switch in the R/H switchblock can also corrode from water ingress over time, a careful dismantling & cleaning of the switch with some contact cleaner & a little brush sorts it out but seeing as you've replaced the switchblock, that may not be your issue.
Edit; The headlights are supposed to turn off when the starter button is pressed, it allows more power to the starter motor.

[Sulli]

Its not a switch it imho appears to be a bad earth connection is there an earth strap missing or the contacts on the earths need to be cleaned on the motor and frame good luck