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post #1 of 13 (permalink) Old 10-15-2008, 11:13 AM Thread Starter
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No electrical power on bike

Here's a nice problem for everyone, I have a 99ZX6r. All the fuses are good including the 30 amp main fuse, battery is showing 12 volts on my tester but when I turn the key on-NOTHING. No background lights on the gauges, no horn, no flashers/headlight not a thing. I wiggled around all the wires by the gauges and ignition just to see if maybe something was a little loose but that was useless. Any ideas?

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post #2 of 13 (permalink) Old 10-15-2008, 12:37 PM
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Here's a nice problem for everyone, I have a 99ZX6r. All the fuses are good including the 30 amp main fuse, battery is showing 12 volts on my tester but when I turn the key on-NOTHING. No background lights on the gauges, no horn, no flashers/headlight not a thing. I wiggled around all the wires by the gauges and ignition just to see if maybe something was a little loose but that was useless. Any ideas?
Did you check for power OUT of the main switch? If you have voltage available to the switch but not out....guess what.
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post #3 of 13 (permalink) Old 10-15-2008, 01:27 PM Thread Starter
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Where's any easy place to check for power coming out of the main switch?

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post #4 of 13 (permalink) Old 10-15-2008, 08:46 PM
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At the main switch coupler. Just back probe it (place the probes in the backside of the coupler) with it connected and put your black lead to ground. You can even use a test light for this procedure. (with the key on BTW)
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post #5 of 13 (permalink) Old 10-15-2008, 10:40 PM
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I had the same problem before. My starter shorted out. Unhook the battery then unhook the starter then hook the battery back up. If your lights come back on its your starter.
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post #6 of 13 (permalink) Old 10-16-2008, 03:34 AM Thread Starter
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Thanks for all the help, I figure it's either the ignition switch or the wire to the switch. I jumped a wire from the battery to the fuse junction box and the lights came on and I could start it, remove my jumper and everything dies. I'll pull the tank and check the switch at the coupler next.

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post #7 of 13 (permalink) Old 10-16-2008, 08:30 AM
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Main switches do get dirty from time to time. I've had to pull them apart before (not on mine but other F models in the shop) And it is possible to clean the contacts up and have them working.

First I would check the switch statically, measure resistance across the terminals with the key in the on position and the coupler unplugged. If there is no continuity, then take the housing apart and clean the contacts. Watch out for the little ball bearing detentes, they are spring loaded and can fly out and get lost.

You will also have to drill out the sheared bolt heads. They are an anti-theft fastener to prevent tampering with the ignition housing.
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post #8 of 13 (permalink) Old 10-16-2008, 10:45 PM
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What exactly did you jump because I have a buddy with a zx7 that has no power and I'm thinkin it might be the same thing
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post #9 of 13 (permalink) Old 10-16-2008, 10:59 PM
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you don't HAVE to drill them out. use a dremel with a 1" cutoff wheel and slot the nubs at the end of the screw. you'll have to cut into the casing a bit, but it's ok.. won't hurt anything by doing that.

after you get a nice lever clean slot on the screw, you can back em out with a small flat screwdriver AND reuse them. sorry the pic sucks, but on the left screw, you can kinda slightly make out the slot i cut into the nib, running vertically.


watch the spring loaded contact block under there!!!!!!!!!!!!!!!!!!


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post #10 of 13 (permalink) Old 10-16-2008, 11:55 PM Thread Starter
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What exactly did you jump because I have a buddy with a zx7 that has no power and I'm thinkin it might be the same thing
Under the seat, I jumped from the battery to the brown wire going into the junction box, it's the hot coming back from the ignition switch I believe.

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