1994 Kawasaki 750SX Weird Electrical Problem

brapperdoodle

brapperdoodle

Location
Asheville, NC
So my brother and I have had this ski for a pretty long while now and it started acting up about 6 months ago. The problem is that when you push the start button you get 1 click from the relay and the ski does not turn over. I diagnosed the problem as best i could and checked the main switch for continuity, I also cleaned it out and rebuilt it with fresh dielectric grease. The switch is showing no resistance and seems to be functioning properly, both stop and start buttons. I have a factory service manual and decided to rebuild the e-box. I replaced all the o-ring seals and used dielectric grease on all of the connections. My brother bought a new regulator rectifier (OEM) also a relay and starter, I checked them using the service manual info. The ski finally turned over, but with a POP i saw a large spark jump from the main starter wire to the exhaust. It is now only doing the 1 click thing and now won't even do that. I re-checked all of the connections and parts per the service manual, all of them checked out fine! I also checked all of the main power and ground wires for cuts or splits, all of them look great and show no resistance. Im really confused and need some help!
 
Jr.

Jr.

Standing Tall
Staff member
Site Supporter
Location
Hot-Lanta
Because you stated a “Pop” ? Im thinking starter is bad? Take a volt meter and ck the positive lead on the starter?
tap the start button and see if you have 12v? this ski is 25 years old now? It can really be anything? Start with the battery itself? Make sure its good? If its 2-3 years old? Its getting ready to be replaced.
cables would be the next item to ck? Just because they physically look ok? Doesn't really mean they are?
do a resistance ck thru them? If questionable? Just replace them. They are too old to try and repair.
the solenoid also is probably worn? Last thing to note, almost all the oem parts for this will now be considered obsolete by Kawasaki. So, you will be stuck buying aftermarket? Do your best to weed out the cheap, junk parts, for the ones with the better rating. Good Luck!
 
brapperdoodle

brapperdoodle

Location
Asheville, NC
I should have been more specific, the battery has been on a trickle charger and is showing 12.6v, it starts the superjet fine. But otherwise I cannot confirm it’s a perfect battery. As far as the cables go, I did check continuity on all of the wires, they show .2 ohms of resistance. All of the ends look solid and not frayed, and the leads themselves are not weak or broken. We cleaned them with a wire brush and put some dielectric grease on them. I agree the cables should be replaced because they are just old.

The “pop” was the arcing I just happened to be looking directly at when it happened. I was juts looking right down near the starter and saw it.

I did confirm with my brother that the starter and starter relay were not OEM parts. I am very aware of cheap replacements, I think it was an effort on his part to “diagnose” the problem and just bought some cheap replacements to see if it would fix the issue. But now I realize it could have created more problems haha. I’m going to try and look closer at it but I don’t have much time before we leave this weekend before Daytona. All is well though!
 
Jr.

Jr.

Standing Tall
Staff member
Site Supporter
Location
Hot-Lanta
Sanoman said:
It is!
Click to expand...

Don, Dont you wrangle me into working next week!

Brap, Your plan is good, outside of the SBT starter! You would be better off getting a good used oem from Zig!
Those cheap china starters are less than reliable, even when new!

P
 
brapperdoodle

brapperdoodle

Location
Asheville, NC
Jr. said:
Don, Dont you wrangle me into working next week!

Brap, Your plan is good, outside of the SBT starter! You would be better off getting a good used oem from Zig!
Those cheap china starters are less than reliable, even when new!

P
Click to expand...

I agree, my brother is hard to get ahold of though haha if anyone has a quality starter in Daytona I will probably try to convince him to buy one. We will be there Monday morning the 13th. I “bit the bullet” for my superjet and ordered a new OEM bendix and starter... they ain’t cheap! But I know it will work haha.
 
Sanoman

Sanoman

thecolorpurple
Location
NE Tenn
Jr. said:
Don, Dont you wrangle me into working next week!

Brap, Your plan is good, outside of the SBT starter! You would be better off getting a good used oem from Zig!
Those cheap china starters are less than reliable, even when new!

P
Click to expand...
That is one of the things l like about Brappadoodle,he likes doing his own builds and repairs!
 
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