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+--- Thread: Fazer rebuild - electrical problem (/showthread.php?tid=71613)
Fazer rebuild - electrical problem - chrisb.91 - 20-02-15
Hi guys, I have recently completed a full rebuild of a 1999 fazer 6 but am having trouble with ignition. When pressing the ignition button the starter relay clicks and I get a fuel and oil light on the dash but the starter motor doesn't spin. I am struggling at the moment because when I try to short out the terminals on the solenoid nothing happens, not even a spark.
Checked -
-Fuel pump spins
-Battery is good
-Tried three working separate solenoids - all click but thats it
-Fuses all in tact
-Checked the main electrical connections but all looks good (bit of corrosion on the engine cut out terminals, but looks as though its still performing)
I may have accidentally plugged something into the wrong point but I don't think that's the case?
Can anyone help? I am Portsmouth based if any one is in the local area?
Cheers Chris
Re: Fazer rebuild - electrical problem - Ebme Geek - 20-02-15
By the fact that your neutral light is still on it looks like it is not a problem with the gound to the motor.
If you have got a meter, check you are actually getting 12volts to the terminal on the starter motor holding the negative lead on a bolt of the motor, if thats ok, looks like you have dicky starter motor, if it was siezed it would still draw power and give a spark when you bridge the large terminals on the solenoid.
So maybe sticky brush, you could try putting the bike in gear and rocking the bike backwards over a compression or two, this will drive backwards through the starter clutch and move the armature in the starter.
Re: Fazer rebuild - electrical problem - chrisb.91 - 20-02-15
Hi Ebme Geek,
I have tested the starter using the battery and its working well but will meter the terminal when i get a chance to be safe.
I will try rocking the bike too, im not sure what else it could be, the build was going so well but the bike has been sat around for a year so i guess there was always something that would cause me some grief.
Thanks
Re: Fazer rebuild - electrical problem - Paradox - 21-02-15
Got any updates with this?
A full fazer rebuild is a hell of a project I'd have thought and I'd like to know what you've done to solve your problem
Re: Fazer rebuild - electrical problem - midden - 21-02-15
Give him chance :rollin :rollin
Re: Fazer rebuild - electrical problem - chrisb.91 - 23-02-15
Hi guys,
Well I am uncovering new problems haha, i split the starter motor and the brushes are fine, so that looks ok. However I tried to rock the bike but it looks like something has seized.... might take a bar to the front sprocket and force a revolution to see if i can free it up. The bike has sat for over a year now without a start so it looks as though there are more problems to come.
I am still stumped that the solenoid doesn't spark when I short it out..there must be a corroded terminal somewhere, just need the time to meter every terminal :l
Such a shame because shes ready to go, clips ons, dominator, mirrors the lot - just need to turn her over.
Any other suggestions guys?
Re: Fazer rebuild - electrical problem - His Dudeness - 23-02-15
You've got the symptoms of a weak battery. Was the battery sitting around in the bike for a year too? If it was it's probably for the bin. They can show 12V and they can even take a full charge but when you hit the starter the voltage drops from a weak cell or two. You could jump it off a car battery and see if it turns over just make sure the car is off. Do you know the history of the bike or the reason why it was parked up?
Re: Fazer rebuild - electrical problem - chrisb.91 - 23-02-15
I have owned the bike for a good 2 -3 years but over a year ago I was hit by a car. The fazer was CAT C with just front fairing damage, I got a pay out and decided I would break the bike for parts. After going through a thundercat and R6 I have decided to challenge myself and put it all back together. The engine was in good working order having just had a full service the week before the crash.
As for the battery, i swapped it with the new one in my R6 but its the same story. Will start metering electrics when I get a day off this week and update you guys.
Thanks for your help and suggestions so far! Eventually I will get there haha
Re: Fazer rebuild - electrical problem - stevie-g1968 - 23-02-15
Take the plugs out before you try to force turn the engine, you could have hydraulic lock if fuel have run through the carbs into the bores... if you try to turn it over like this you will bends the con rods.
Re: Fazer rebuild - electrical problem - Ebme Geek - 23-02-15
What gear did you try rocking it in ? 1st is quite hard to get it to go over a compression
did it seem the engine moved at all or absolutely solid ?
When you take the plugs out check them for any sign of corrosion,
How was it stored while it was not run ?
were the carbs and exhaust on the engine ?
any chance cylinder bores and rings have rusted up ?
Rather than putting a bar on the sprocket, I would take the alternator cover off then you can feel the crankshaft directly by carefully turning the flywheel with it in neural, (it's dry, no oil behind this cover).
If it don't want to move, does it rock slightly or solid ? > more investigation before trying to force it
Re: Fazer rebuild - electrical problem - Ebme Geek - 23-02-15
going by what you have put, I should have put,
make sure the motor is free and smooth turning before cranking with the starter
And depending on how you progress bare in mind the clutch maybe sticky having been left, so if you get it running make sure the clutch will clear before banging it in gear while the motor is running
Re: Fazer rebuild - electrical problem - chrisb.91 - 24-02-15
Hi guys thanks for all your comments. After a year of sitting in a cold garage, one month rebuild and one month of problems she starts, runs and moves!!! Happy days, i was literally so excited I ran around in circles. Iin answer to Ebme and Steves last comments - they were great suggestions and as a last resort I tried force haha. I think the revolution I put through it gave the starter a better start and after a minute or two she spluttered into life.
Now I just have to do fluids, fabricate a clock bracket, install clip ons and complete a dominator wire up - that being said has anyone got a working link to the fazer headlight mod? I can find a wiring diagram for a twin dominator to save my life.
Thanks again guys, I will post a couple of pics when shes all sorted.
Re: Fazer rebuild - electrical problem - Paradox - 25-02-15
Wow, well done Chris!
Full strip and reassemble I wish I could do that (and have it resemble a fazer at the end)
Re: Fazer rebuild + - chrisb.91 - 25-02-15
As promised I have some pictures to show you guy what the bikes gone through!
So there is before the crash.
Damage caused
Half way through the rebuild
And what she looks like as of today.
Re: Fazer rebuild - electrical problem - Tommyk - 25-02-15
Nice one would love to see pics with clipons
Considering clip ons for my naked fazer
Re: Fazer rebuild - electrical problem - chrisb.91 - 25-02-15
Clip ons are in the post, as soon as they arrive il fit em and takes some photos for you mate. So excited to get her back on the road again, feels good!
Re: Fazer rebuild - electrical problem - chrisb.91 - 05-03-15
So clip ons are fitted and the bike flew straight through its MOT! Happy days. I have had to order a new master cylinder because the brake reservoir on the fazer slightly fouls on the clipon bracket but for now it will do. Just need to fabricate another bracket for the speedo and then on to the next job; replacing the swing arm, airbox and front end.