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ZZR600 Very Intermittent Starting Issue

3K views 5 replies 5 participants last post by  Jeff in Kentucky 
#1 ·
So this only occurs about once every 20 starts or so it seems. After I think I remedied the issue it seems to happen again. Occasionally when I push the starter absolutely nothing happens. No clicking from the relay, dash doesn't dim, nada (In neutral with the run switch ON). Then it all of sudden starts right up after multiple starter button presses.

I have checked the battery terminals multiple times, cleaned and dielectric greased them. I also checked the starter relay connections and used electronic cleaner on the fuse holders. I have opened the starter/kill switch and did not see any signs of corrosion. I also checked the positive wire that connects to the starter. I have another starter relay on the way, but I was just wondering if there is anything else I should check out.

The only other thing I can think of is the starter button and/or kill switch is not making a good enough connection, but my bike never dies spontaneously which I would expect from a kill switch issue.

Some similar threads have people recommending changing the clutch/kickstand switch, but these only come into play when the bike is NOT in neutral, correct? So I do not think they could be the culprit.
 
#3 ·
You can pull the relay and bench top test it if you have a spare battery, or maybe a 9V will work (I may test this myself actually). Anyway, you can put voltage across the relay and hear it pick up several times to see if is falling. I'm guessing maybe your start button may be the problem otherwise. You're right though, if the bike is in neutral, then the safety switches won't prevent the bike from starting if they've failed. Good luck.
 
#4 ·
Try spraying a lot of WD-40 inside the start switch. If that does not work, the start switch might need to be taken apart and cleaned, or replaced.
 
#6 ·
I spray WD40 inside the handlebar switches about once a year, to prevent problems from rainwater and condensation. A special electrical contact cleaner might work even better, especially if you already have a problem. If your bike is stored outdoors this should be done a lot more often.

For the turn signal switch, some Fluid Film sprayed in it makes it slide to turn on or push to turn off much easier.
 
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