mwrzx12
Expert Class
Posts: 115
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posted October 13, 2002 05:16 PM
Need Help With Strange Electrical Problem
My 02 is doing something very strange. It will only start if it is in neutral with the clutch out. If you pull the clutch in it will not start (it does not matter if it is in gear, kickstand up or down).
After it starts it runs and acts normal.
I don't recall doing anything to cause this to happen.
Has Muzzy full system, PC111r, Yellow box...but I don't think any of that would matter?
02 with 4000 miles, has anyone ever had this problem?
Only thing I have tried is disconnecting the clutch lever switch, and the bike would not start at all.
Any ideas would be appreciated.
  
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ZHooligan
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posted October 14, 2002 05:03 PM
You have baffled me. Let me give this some more thought.
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mwrzx12
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posted October 14, 2002 05:29 PM
I checked all the fuses..none blown.
The clutch sensor is clean, seems to be fine.
Thats all I had time to check.
Going to try and check the kickstand switch tomorrow,
its not very dirty...I'm baffled myself.
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aliveagain
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posted October 14, 2002 05:53 PM
did you just wash the bike?
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mwrzx12
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posted October 15, 2002 03:08 AM
No. Not just washed and have not been in the rain but one time a couple of months ago.
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TurboBlew
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posted October 15, 2002 03:31 AM
Try jumping the kickstand switch. Also look at the connectors close, I just found a connector on my 02 that came out of a harness plug.
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mwrzx12
Expert Class
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posted October 15, 2002 03:33 AM
Thanks. I'm going to pull the left side fairing off tonight where I can get to all the connectors.
And I will clean the kickstand switch also and make sure everything is clean and connected correctly.
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aliveagain
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posted October 15, 2002 05:08 PM
sounds like the starter cutout switch is not right.the manual says to check voltage as per page 15-30 interlock operation onside stand, lock out,gear position switches and if those are good replace the ecu
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mwrzx12
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posted October 15, 2002 05:33 PM
I went out and checked everything I knew to check.
I could not find any connectors loose.
Everything is clean, and no water has been on it.
I don't know how to do the check you described aliveagain. I appreciate the help, but it may have to make another trip to the dealer. It is under warranty, I just hate taking it in. Thanks again for your help.
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DaveInDaytona
Pro
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posted October 16, 2002 04:40 AM
quote:
My 02 is doing something very strange. It will only start if it is in neutral with the clutch out. If you pull the clutch in it will not start (it does not matter if it is in gear, kickstand up or down).
It's working as designed. Look on page 63 of your manual.
"The motorcycle is equipped with a starter lockout switch. This switch prevents the electric starter from operating when the clutch is engaged and the transmission is not in neutral"
I tried it on mine, you can hear the fuel pump run if you pull the clutch and push the starter while in neutral, but it won't crank. Release the clutch and it cranks. There's a starter lockout switch on the clutch lever, it's supposed to do that.
Dave
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mwrzx12
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posted October 16, 2002 05:13 AM
But Dave, won't your bike start while in gear with the clutch pulled in?
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DaveInDaytona
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posted October 16, 2002 05:41 AM
quote:
But Dave, won't your bike start while in gear with the clutch pulled in?
Just went out to try it to make sure. No.
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mwrzx12
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posted October 16, 2002 05:46 AM
Thanks Dave. So there is no problem. I must be getting senile in my old age. I have always just started it in neutral before I get on it, and I have never stalled it.
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frEEk
Administrator
ummm... yeah
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posted October 16, 2002 12:25 PM
well, mine will definitely start in gear so long as the clutch is pulled in. have had to do so many tiems when stalling it while rolling. pull in the clutch, restart while rolling, and continue on yer way. plus bump startin would be damn hard otherwise. plus i thought u originally wrote that it WOULD NOT start with the clutch pulled in no matter what? still sounds like a switch somewhere is not quite right. almost certianly the clutch switch i think.
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mwrzx12
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posted October 16, 2002 12:33 PM
Freek you are correct. Mine WILL NOT start with the clutch pulled in no matter what. If I am understanding Dave he is saying his will not start with the clutch pulled in either?
The manual is a little confusing to me as to whether it should or should not start while in gear, with clutch pulled in, as in the case where you have stalled the bike and need to restart.
I'm still confused.
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DaveInDaytona
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posted October 16, 2002 07:58 PM
OK, now you got me thinking something is wrong. I'm going to trace everything and run all the service manual checks. Why ? Well this is behaving differently than my other 12 did. If I put it in gear with the clutch pulled and the stand down it kills the engine.
freek, you don't use the starter when you bump start so this would have no effect (unless it's one of those Canadian things)
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frEEk
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ummm... yeah
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posted October 16, 2002 10:02 PM
good point on the bump start. but my startin while rollin after a stall still stands. i'm pretty sure u guys got something wierd there, or it may be something regarding differeing state legislations?
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havabusa12r
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posted October 17, 2002 12:29 AM
 Edited By: havabusa12r on 21 Oct 2002 12:57
I have an '02 also. I have the same PROBLEM? I found out on the road when I could NOT start my bike the same way that I had been.
It will now only start in neutral with the clutch lever OUT.
I had a dealer checking it in Montana, I have my local dealer ready to check it here.
My 00 was not like this. There IS definately a problem.
The Kaw SHOULD start in gear with the clutch lever IN and the sidestand DOWN. It will (should) NOT kill the engine until the clutch lever is SLIGHTLY released. (no other brand of bike that I've owned will let you start in gear /sidestand down- I just tried my busa and RSV Mille)
I thought it was designed this way beacuse even with the positive nuetral finder, you can't find neutral.
It makes no sense? to be able to start ONLY with the clutch lever OUT?
It is probably recall time, but I NEVER had a prob with my 00.
I am also around 4,500 miles. I wonder what part # is different?
Ray
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(99 Copper Busa) (99 Duc 900 SS full fairing) (00 MV Agusta F4S) (02 Aprilia RSV Mille) (02 ZX 12r CTB) (03 KTM 950 Adv)
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havabusa12r
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posted October 17, 2002 12:39 AM
BTW-
The dealer in Mt checked the clutch swith and it was OK.
His 'guess' was that it was one of the relays?
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(99 Copper Busa) (99 Duc 900 SS full fairing) (00 MV Agusta F4S) (02 Aprilia RSV Mille) (02 ZX 12r CTB) (03 KTM 950 Adv)
(04 Yam R1) (05 LE Busa) (07 ZX 14)
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mwrzx12
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posted October 17, 2002 03:24 AM
Guys I appreciate the help. I felt like something was wrong. I was sure it would start before with the clutch lever in, but I started questioning myself.
Keep us posted if anyone finds out what the problem is.
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DaveInDaytona
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posted October 17, 2002 06:47 AM
Well it just so happens that there are a bunch of people from Kawasaki in town, with a bunch of new Kawasakis. I think I'll swing by and see if any of them know anything. I doubt the "expert" is there but they might know how to contact the person who can tell us what's normal operation.
Dave
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DaveInDaytona
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posted October 17, 2002 07:43 AM
Edited By: DaveInDaytona on 17 Oct 2002 08:44
OK, I stand corrected. Some of what I said is true, the other part I'm writing off to me not understanding your question.
I talked to Kawasaki a few minutes ago and described the problem. I was told to look at the clutch switch because it sounded to him (a 12 rider that had the same issue recently) like the switch had dirt in it. If you're comfortable doing it you can take it off and pull it apart to check it, it needs to be fully extended to make contact. If you don't want to pull it apart and want to try a quick fix, do this. Pull the clutch lever in and hold it. Take a small flat blade screwdriver and depress the clutch switch all the way in, when it's all the way in let it pop back out. Do that a few times and I'll bet it will be working ok again.
Dave
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DaveInDaytona
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posted October 17, 2002 07:47 AM
Oh, I did my "quick fix" and it worked for me. I can now start it in gear with the clutch pulled.
Dave
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mwrzx12
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posted October 17, 2002 07:52 AM
I'll try that Dave. I have disconnected mine under the clutch lever and did not notice any dirt inside the connection. I'll recheck and clean very good tonight and let you know if it fixes mine as well.
Thanks for all your help.
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DaveInDaytona
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posted October 17, 2002 07:59 AM
It's not the connector part but inside the switch that seems to have the problem. Must be dirt getting in where the pin that touches the lever comes out. The switch can be popped open to see if you're up to taking it off and apart but that's more than some people want to do. With the wire off the switch it acts just like the clutch is out.
Have fun,
Dave
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