Looking For Guidance On Helping Me Off The Ledge

Hi. I am back. Happy Easter everyone.
New to me wiring harness installed. It is unmolested and cleaned up pretty well. I put in new fuses on the main fuse box.
I have done all of the previous checks and get good numbers all the way to the cylinder head. Key on.
I hoped that it would turn over with the button to see if the spark plugs have spark, but no joy. I could jump the solenoid but I was hoping to avoid that. It does not have the "clutch must be engaged" installed on this harness.

Suggestions welcome.

Have you checked the kick stand switch.  Should be able to bypass that.

Man I rolled one of mine out of the dealer in 1981. I don't remember the side stand switch ...

Two areas I want you to look at.
1. is the starter solenoid.(blue circle)

meter on DC V
key on
ignition switch set to run
all connectors connected

black probe on negative battery post
red probe on positive battery post
note voltage

on the solenoid find the small black wire with yellow stripe.
you'll need to backprobe that connector with the red probe.
voltage should be close to 0.0v

The other small wire on the solenoid is yellow with a red stripe. That wire connects to a solid black wire no stripe.
With those two wires connected to each other backprobe that connector with the red probe.
Push the starter button. You should see battery voltage on the meter when you push the button. When the button is not pushed you will see close to 0.0V.

You can also hold a compass next to the starter solenoid. When you push the starter button the needle on the compass will swing (you could use a compass app on your phone as well).

The other area is the starter safety switch.(red circle)
Trace the solid black wire going to the starter solenoid.
That wire goes to a safety switch. At the switch there is another black wire that goes to the starter button.
Make sure those two black wires are connected to the switch.
Backprobe each black wire at the switch with the red probe.
Press the starter button and note the voltage at each black wire at the switch.
You should see battery voltage at each wire when the button is pressed.


turn off bike




 

Thank you.

How do I backprobe? Does that mean pierce the wire itself?

Also, FYI, my solenoid does not have a yellow and black wire. It's black OR yellow. I assume I test the black?



 

Do not pierce the wire (this will become a point of failure later when the moisture gets in) go in the back of multi plugs with you meter probe or with bullets slide the probe under the sleeving

Was the new wiring harness from a 1981GPZ KZ550D1? As your wire colors and options may be different with the new harness.


You just slide the probe from the back of the connector underneath the clear rubber cover.
You can use a nail or needle if your probe isn't thin and long enough.
Wookie is correct.. you don't want to pierce the wire. It will be a site where corrosion will enter the wire.

photo: mechanics.stackexchange.com/questions/39...lated-short-circuits

 

I was able to perform two of the tests. I need a third hand to do the starter button test. But ...

<<<on the solenoid find the small black wire with yellow stripe.
you'll need to backprobe that connector with the red probe.
voltage should be close to 0.0v

The other small wire on the solenoid is yellow with a red stripe. That wire connects to a solid black wire no stripe.
With those two wires connected to each other backprobe that connector with the red probe.>>

Key off both tests were zero.

Key on the first one was 70-74 moving constantly.

Key on the second one was 70.9

I'm never going to be able to find the starter safety switch I fear. Is it inside the starter button clasp? Or is that the same thing as the neutral safety switch under the sprocket cover?
I hooked up the signals and tail light last night. Aside from no flashing that part is good. Also horn button does not work yet.

Thanks!

Mini-update of no joy.

I have a running GPz550 right next to this one. I pulled the start button clasp off the running one and put it on the one on the bench. Prayed. No dice. Nothing at the starter button. No change.

chopper1963 wrote:

Mini-update of no joy.

I have a running GPz550 right next to this one. I pulled the start button clasp off the running one and put it on the one on the bench. Prayed. No dice. Nothing at the starter button. No change.

If you look towards the end of the fault finding guide in my signature there is a test plan for the starter circuit

chopper1963 wrote:

I was able to perform two of the tests. I need a third hand to do the starter button test. But ...

<<<on the solenoid find the small black wire with yellow stripe.
you'll need to backprobe that connector with the red probe.
voltage should be close to 0.0v

The other small wire on the solenoid is yellow with a red stripe. That wire connects to a solid black wire no stripe.
With those two wires connected to each other backprobe that connector with the red probe.>>

Key off both tests were zero.

Key on the first one was 70-74 moving constantly.

Key on the second one was 70.9

I'm never going to be able to find the starter safety switch I fear. Is it inside the starter button clasp? Or is that the same thing as the neutral safety switch under the sprocket cover?
I hooked up the signals and tail light last night. Aside from no flashing that part is good. Also horn button does not work yet.

Thanks!

I hope you aren't connecting the two small wires on the solenoid together - in this state operating the starter button with the ignition on will cause a "dead short" this will probably blow the main fuse however given the mainfuse takes approx 25 amps to blow and this circuit is rated at approx 2amps there is a risk the wiring will burn before the fuse blows

I'll chime in after dinner.

Ok, let's clarify the last test.
Meaning let's do this again with the help of your photo.

Key ON
Kill switch set to RUN
meter DC V

Black probe on negative battery post.
Red probe slide under connector boot following the red line(connector must remain connected)
what is your voltage?
Press starter button
what is your voltage?

Move red probe under boot following blue line
what is your voltage?
Press starter button
what is your voltage?

You should be able to wedge the meter probes under the boot while you press the starter button.

The safety switch should be at the kick stand or at the clutch lever.
I'm too lazy to search for a service manual.
Other members may know where the safety switch hides.

Turn off bike