Author Topic: Stone dead (Read 1771 times)

M.A.N. · « **on:** 22 July 2023, 07:23:35 pm »

Took my Fazer 2003 for a drive. Stopped for a few minutes at a parking lot but then it did not start - absolutely nothing happened when I turned the key / pushed the start button. Thought it might be the battery so tried to bump start it but not even the slightest tendency to ignite. Back home I started to check the battery and this is OK (12.5V). Checked the main fuse, also OK. Thought is was the starter relay as there in no 'click' when start button is pushed, so replaced it but still stone dead. Before when it was working, there was always a ticking sound for a few seconds when I turned the key, but this is also gone.

I am out of options now

. Anyone who can guide me in the right direction? Thx!
//Mats

unfazed · « **Reply #1 on:** 22 July 2023, 08:46:39 pm »

Do he dash lights come on when you turn on the key?

M.A.N. · « **Reply #2 on:** 22 July 2023, 08:49:27 pm »

Yes - lights working as usually.

darrsi · « **Reply #3 on:** 22 July 2023, 08:56:46 pm »

Out of interest, what did you pay for a new starter relay?
There are some dodgy ones about, I bought a cheap one and it literally fell apart after a few months resulting in zero power.
The prices vary quite a bit.

M.A.N. · « **Reply #4 on:** 22 July 2023, 09:09:46 pm »

Paid some £50 or so. Bought it from a big MC parts dealer. But I can always try to check it acc.to the routine in the workshop manual, just to rule this out.

unfazed · « **Reply #5 on:** 22 July 2023, 09:17:31 pm »

When you pressed the starter button did the warning lights on the dash come on and go off?

M.A.N. · « **Reply #6 on:** 22 July 2023, 09:31:56 pm »

When I turn the key, 3 lamps light up: The green light for the neutral gear, the red for the oil and a yellow for the gas. Within a second the two last is off and then only the green remains. Can't recall what happens when I press the start button so have to check this but I remember that all lights on the dashboard was flashing when it occured the first time.

unfazed · « **Reply #7 on:** 22 July 2023, 10:04:00 pm »

Was the bike in neutral when you tried it? Is the Kill Switch in the on position?

M.A.N. · « **Reply #8 on:** 22 July 2023, 10:35:27 pm »

Bike in neutral. Tried to switch the kill switch on and off a couple of times just to make sure I did not press it by accident, but did not help. Will try to check tomorrow if it might be defective/corroded.

BBROWN1664 · « **Reply #9 on:** 23 July 2023, 10:54:53 am »

put the bike on the main stand, put the side stand up and pullthe clutch lever in. Make sure the bike is in neutral and then press the starter button. Do all the dash lights (oil etc) come on when you press the start button now?

TOM VR46 · « **Reply #10 on:** 23 July 2023, 11:46:59 am »

Another wee test for you to try. Side stand switch. You said you stopped so guessing side stand went down. So had wee look back on posts and on page 5, STARTER NOT WORKING , by festerbestertester. Worth checking.

M.A.N. · « **Reply #11 on:** 23 July 2023, 09:09:54 pm »

@BBROWN1664: No reactions from the dash lights@TOM VR46: Interesting post, thx. So checked the operation of the sidestand switch and got continuity with sidestand up, so all good. Clutch switch also fully functional.

Starting to suspect the issue is related to the Starter Circuit Cut-off Relay as this is connected with the fuel pump that suddeny got silent (no more ticking sound when turning the key). See if I can manage to check it and order a used one on Ebay. Will post the outcome when part has arrived.

BBROWN1664 · « **Reply #12 on:** 23 July 2023, 09:34:23 pm »

Quote from: M.A.N. on 23 July 2023, 09:09:54 pm

@BBROWN1664: No reactions from the dash lights@TOM VR46: Interesting post, thx. So checked the operation of the sidestand switch and got continuity with sidestand up, so all good. Clutch switch also fully functional.

Starting to suspect the issue is related to the Starter Circuit Cut-off Relay as this is connected with the fuel pump that suddeny got silent (no more ticking sound when turning the key). See if I can manage to check it and order a used one on Ebay. Will post the outcome when part has arrived.

No reaction from the dash lights suggests the start switch circuits do not think the start switch is being pushed. The dash lights will come on if the bike is in gear with the side stand down etc and when everything is working normally (you just dont see them as you relase teh button quickly)

you need ot investigate the wiring diagrams relating to the starter switch.

Maybe check the main fuses again.

unfazed · « **Reply #13 on:** 24 July 2023, 12:37:05 am »

Quote from: M.A.N. on 23 July 2023, 09:09:54 pm

@BBROWN1664: No reactions from the dash lights@TOM VR46: Interesting post, thx. So checked the operation of the sidestand switch and got continuity with sidestand up, so all good. Clutch switch also fully functional.

Starting to suspect the issue is related to the Starter Circuit Cut-off Relay as this is connected with the fuel pump that suddeny got silent (no more ticking sound when turning the key). See if I can manage to check it and order a used one on Ebay. Will post the outcome when part has arrived.

I would be thinking the Starter Circuit Cut Off Relay box also or corrosion in the plug and pins of the box.
They are a rare failure but have seen a few with burned out diodes inside. Diodes can be replaced, but when the failures are rare a second hand one is worth buying. Check the plug going into the box for the dreaded green corrosion. I have seen a few with similar issues to yours and the plug and pins were badly corroded.The kill switch supplies the power to the box on a red black wire, two relays in the box, one is the cut out relay and the other is the pump relay.Pull the plug and check you are getting 12v on the wire switching on and off the kill switch should turn on and off the 12v with the ignition on of course.

M.A.N. · « **Reply #14 on:** 03 August 2023, 04:25:54 pm »

Replaced the Starter Circuit Cut-off Relay and now the bike is running again

. Thx for all support!

darrsi · « **Reply #15 on:** 04 August 2023, 03:23:49 am »

Is a "Starter Circuit Cut Off Relay" a long version of saying a Starter Relay unit?

unfazed · « **Reply #16 on:** 04 August 2023, 02:35:59 pm »

Starter circuit Cut Off Relay is a more accurate term for it since is is more than a relay.

The starter relay would be the wrong term as the Solenoid is technically the starter relay.
Unfortunately both terms are used for it

M.A.N. · « **Reply #17 on:** 12 August 2023, 02:24:37 pm »

Seems it is also frequently known as the 'Fuel Pump Relay'.

darrsi · « **Reply #18 on:** 12 August 2023, 05:10:16 pm »

Quote from: unfazed on 04 August 2023, 02:35:59 pm

Starter circuit Cut Off Relay is a more accurate term for it since is is more than a relay.

The starter relay would be the wrong term as the Solenoid is technically the starter relay.
Unfortunately both terms are used for it

So the one I replaced recently is the Starter relay/Solenoid, that sits right behind the battery under the seat.

Where does the other one live?

If I put fuel pump relay in Ebay just a fuel pump comes up.

unfazed · « **Reply #19 on:** 13 August 2023, 12:34:30 am »

Under the left side cover

darrsi · « **Reply #20 on:** 13 August 2023, 06:44:53 am »

Quote from: unfazed on 13 August 2023, 12:34:30 am

Under the left side cover

Alrighty then. Something new i learned today