KZ550 starter problems

[xssiveone]

Well, it seems that if it isn't one thing, it's another lately. When I was in Picton last weekend, the starter switch (or so I thought) started acting up and only working occasionally. No problem I thought, I'll just clean it when I get home. Switch has been cleaned, wiring checked, and I have power all the way to the starter solenoid when I hit the button. But.. the starter won't spin. Check the solenoid, no power coming out of it when I hit the button. Aha!! the soldenoid must be bad. Managed to find a suitable replacement.. fab the wiring so it will connect, install both cables on it, hit the button and listened to absolutetly nothing. Just the clicking from the starter circuit relay. Still have power to the solenoid, still have no power coming out when it won't start. Heading further downstream to check the cable at the starter and the main ground cable.

The really strange part is that I can short across the posts (battery to starter) and the bike will start. And if I repeatedly hit the starter button, it will eventually spin over and start.

Any ideas are greatly appreciated.


2nd problem that reared it's ugly head was the right side exhaust breaking in front of the muffler. Anybody have a good used one, stock or otherwise? No aftermarket or stock systems are available in Canada... stock is available in the US, but only as a last resort.

[CMA1]

Exhaust replacement

There is a 4 into 1 system from MAC Canada available....
http://www.mcdistributing.com/index0...hp?model=kz550 but maybe you want to keep it OE .
- Larry

[xssiveone]

Thanks Larry. I saw that one, but it's only up to '83. My local dealer, (been around for about 25 years) claims it won't fit. Apparently they changed the frame design from '83 to '84. If I knew it would mate up to the engine, I would buy and make the rest fit somehow.

[xssiveone]

Just sent them an email, maybe they have something else that will work. Not too concerned with the noise factor, but I've always liked a 4-2 instead of 4-1. Not going to get picky at this point tho.

[Geezer]

I think you have a second bad starter relay. If you can jump the post and it will spin, then it has to be the relay. Some of them cah be taken apart and cleaned. I'd try that before buying another one.

If there is enough space for an aftermarket muffler to slip on the pipe, then I'd put a pair of Harley Sportster mufflers on it. They're cheap, good quality and look nice.

Geezer

[xssiveone]

I think you have a second bad starter relay. If you can jump the post and it will spin, then it has to be the relay. Some of them cah be taken apart and cleaned. I'd try that before buying another one.

This one is a sealed unit, so cleaning is not an option. The factory one can be disassembled to clean the contacts, but it's the solenoid portion that is failing, and not the contacts. I'm going to check thru the wiring again.. maybe there is something I missed. I agree tho, everything points towards another bad relay.

If there is enough space for an aftermarket muffler to slip on the pipe, then I'd put a pair of Harley Sportster mufflers on it. They're cheap, good quality and look nice

That very plan was disscussed with a friend of mine who does a lot fabricating. He has the bike right now, and has managed to repair the broken exhaust, but in his words "it's full of holes. replace it" I think he added a couple pounds of bronze from what he was saying. If I can find a good set of header pipes then the slip-on mufflers are not a problem.

[Geezer]

It shouldn't be too hard to come up with a replament relay. It's the most interchangeable part on Japanese motorcycles.

Your friend is wright about the pips, once the headers start rottong away, it's time for new pipes. I have a 4 into 1 KerKer for my KZ650 and it's much lighter than stock. Watch eBay something is bound to turn up.

Geezer