SXR HELP ski starts without lanyard on

[Mr Hyde22]

I need some help. I just got done having my engine out and adding a few goodies but now I am having a strange problem I cannot figure out.

I got it all back together and in the ski and I got the ski started and it was running good (only for a 45 to 60 seconds) I went to hit stop button and it would not shut down. I pulled the lanyard and still would not shut down so I pulled a plug wire and she died.
A little while later when the ski was cold I tried to start the ski with out the lanyard even connected and it turned over so I thought it was the switch.
I found in my manual how to ohm it out and it seems to be working to me - when I pushed the stop button the ohms went to 0.3 does that mean the switch is good or bad?

I also opened the electrical box because I did install a MSD Coil and I wanted to check all my connections and make sure no wires were pinched off and everything looked good in there.

What should I do next? What should I test? Or is my switch bad?

 

[D-Roc]

did you check the kill switch plug in the wire harness? maybe not plugged in all the way?

 

[Mr Hyde22]

the plug seems to be plugged in all the way.
But I cannot get any ohms at the stop button wires inside the electric box with the plug connected. Should I be able to get an ohm test at the stop button wire ends in the electrical box? The ohm test would go from the stop button thru the plug connector into the electric box and then I disconnected the wires in the electric box and tried to test for ohms there but got nothing.
Maybe that means the plug connector is my probelm?

 

[D-Roc]

did you miss a ground wire somewhere? check it at the plug connection to see if it works at least that far.

 

[Mr Hyde22]

I just ohmed it out from up at the stop button itself to the negitive battery terminal and I got .4 ohm , so I think my grounds are good?

I did put a stock lightened flywheel in the ski but I was very careful to make sure the wires were clear when I put the cover back on. I think if any wires by the stator were cut I would not get the engine to turn over , correct?

HELP I want to ride my jetski and be able to shut it off when needed.

 

[D-Roc]

what year sxr is yours? if your lanyard is not plugged in does it de-activate the start button? check with your start button wiring to make sure that it is funtional. If the the kill switch checks out from the actual buttons to the harness plug then you have to search onward. it almost seems like your missing a ground to kill the power but am not 100% sure how the kawi actually stops the spark, it may differ from the 03 ignitions to the new +04

 

[Mr Hyde22]

It is a 2005 sxr. I will look into the start button being the problem. I agree with the ground therory but I ohmed it out to the negitive on the battery and it had 0.4 ohms so I think it is grounded but I could be wrong. I will also check into a missing ground but I dont know where it would be as everything I see is hooked up and grounded.
Thanks for giving me some ideas on this problem.

 

[D-Roc]

i was thinking you may have missed one in the e-box while installing the coil, maybe one slipped off somewhere. just a thought.

 

[Mr Hyde22]

I will look into the ebox again and look for a missing ground but I took a jumper wire and hooked it up to the ground wire for the stop switch in the ebox and then to the neg. battery terminal and with the lanyard off the ski still tried to start.
Could the black box inside the ebox be bad? How do I test that to check?
Does anybody know what the stop button does on a 05 sxr? Does it put the system to ground to turn off the ski or does it disable the start circuit some how?

I am thinking about replacing the start stop switch just to rule that out (even though it tested out to 0.4 ohm so I think it is good) but I cannot find one for sale does anybody have a kawi sxr start stop for sale?

 

[Mr Hyde22]

Any Kawi guys out there have any info for me on this problem.
Please help!!

 

[Mr Hyde22]

Does anyone think this could be a bad CDI Ignitor?

 

[D-Roc]

cdi are one of those things that tend to go bad and just not work, did you double check inside your e-box?

 

[Mr Hyde22]

yes I did and everything is connected and grounded and clean.
I took a jumper wire from the ebox to the block to make sure it was grounded out and it still tried to start without the lanyard. I jumped out the two wires for the stop switch right inside the ebox and it still tried to start without the lanyard connected.
I dont what else to test or check and I was told by a jet ski mechanic that it may be the CDI Ignitor so I think I may get a new one of those and hopefully it will fix my problem unless some one thinks I should try a different cheaper part first. Or if some one knows how to test some thing that I have not tested yet.
Thanks for your help to try and solve this problem.

 

[D-Roc]

hmmm so lets just recap for a moment here. your stop button is making a circuit when pressed. it does so at the wiring connection and in the ebox. your start button also make a circuit when pressed at the wiring connection and inside the ebox. the ski starts without the lanyard plugged in. the ski does not shut off when the lanyard is pulled. (obviously). ski does not shut off when the stop button is pressed. i think that the lanyard disconnects the start circuit when pulled, so the starter motor will not turn the motor over when the start button is pressed. when you plug the landyard in, it disconnects the kill circuit (that kills the motor) and enables the start circuit. I know i could figure this out if the ski was in front of me but it is very difficult to tell what it is you have done to test that your start/stop switch is functional. i would hate to see you buy some new parts and not fix the problem.

 

[Mr Hyde22]

I just went back to the garage to retest the start and the stop switches and yes they ohmed out to 0.00 both at the connector plug and in the ebox. I decided to try and jump out the start switch wires in the ebox to rule out a bad start switch and I realized I had the CDI Ignitor in the house but I jumped it anyway and the ski still tried to start ( that is it tried to start without the CDI plugged in at all) so how can my CDI be the problem if the problem happens without it hooked up. It also tried to start with the start button with out the CDI plugged in. Whats up with that?

 

[D-Roc]

the start button should send 12 volts to the starter relay when pressed. this will tell the relay to connect and send the main 12v to the starter. if the lanyard has been pulled the start button shouldn't be able to send the signal to the relay. i would take the buttons apart and look at you kill switch/lanyard inside of the housing on the bars. also disconnect the the kill switch wire, and plug in the lanyard clip. check the ohm between the black and white wire. now press the kill button. did it change the ohm reading?

 

[Scorn800]

The motor can be turned over without the cdi in. Remember just because the motor is turning over does not mean you have spark.

 

[Mr Hyde22]

The inside of the kill switch is perfect no rust or corrosion it looks brand new in there. When I test the kill witch I disconnect the four prong plug in the wire harness before the the wires go into the ebox and I put my leads to the white wire connector and the black wire connector and my meter reads ol (i believe it is out of limit) then when I push the kill button or I pull the lanyard the ohm meter reads all zeros 0.00. It does the same thing when I put that plug back together and test the white and black wires in the ebox. It also does the same reading when I test the start button in both places.

is that really how the kill switch stops the motor , by making the start button not send the signal? Because when the start switch is not being pushed in it is not completing a circuit , once it is pushed in that is only when the circuit is being completed allowing the power to go thru it to the starter. So with the ski running and the start button not being pushed in it is kind of out of the loop and I am not sure if the kill button being pushed is going to effect the start button circuit. I was told that when the kill button is pushed in or lanyard pulled it grounds out the system thus shutting it down. One test I did was to put a jumper wire from the ebox case to a head bolt to make sure it was grounded and it still tried to start without the lanyard installed and I also did a jumper wire from the bolt that my ground wires goto in the ebox to the motor and to the negitive post battery and it still tried to start.

Should I take off my front cover and check anything inside of there (its going to suck opening that up with the engine in the ski already) where the stator and flywheel live.

 

[Mr Hyde22]

good point scorn. My problem is that the ski can turn over without the lanyard being installed or with the kill switch being pushed in.
Any thoughts on what else I could test to find the problem here?

 

[WFO Speedracer]

Does it have a stop switch relay,I know most of the older Kawis did,I really haven't been into any newer Kawi elect boxes in a while here.If it has a stop switch relay thats your problem.