starter clutch?

[4wred]

Hi guy's
Just bought a fzr 600,been sitting for years.Iv'e worked on bikes before(goldwings) Anyway started to work on today got to the point of trying to fire it up but the starter spins but doesn't turn the engine.
Checked under the peanut cover all looked okay in there,so I spun the starter with the cover off and its turning the clutch in the wrong direction?? It's turning the gear behind the clutch counter clockwise.
If I pull the idler gears out and turn the gear behind the clutch by hand clockwise it engages the clutch turn the other way it spins freely.It seems to me the starter is turning backwards?? Never heard of that before.I checked all the connections to the starter and they are all in order.Am I missing something??? Thanks in advance for any help

[4wred]

Well after further inspection:
The previous owner had the engine ground wire hooked up to the start solenoid instead of the starter cable.
Hooked up the wires correctly and the starter clutch works properly,it was turning backwards!
Tried to fire up the bike and won't start,checked to see if I have spark and I don't.wondering now if those cables hooked up wrong blew something out in the ignition system?? Somebody was working on this bike that probably didn't know what they doing.Hope there's not alot of other things played with

[4wred]

Looks like may have taken out the diode in the main relay due to the p.o. wiring the solenoid wrong,checked the pins on the relay as per the manual and had no continuity (blue/yellow- sky blue).Do these pins create a no spark condition?

[DonTZ125]

Yes. The Blue / Yellow is your 'Safety' pin; if it isn't grounded, either through the neutral switch or the sidestand switch, there is no spark.

[4wred]

Yes. The Blue / Yellow is your 'Safety' pin; if it isn't grounded, either through the neutral switch or the sidestand switch, there is no spark.

Thanks for the reply,thats good news I guess. I ordered a new relay Thursday,most money I've ever spent for a relay.Gotta pay to play!!

[DonTZ125]

Actually, it's two relays plus a bunch of diodes and resistors for the safety switches and oil-lamp self-check. I'd LOVE to sell my own (at a fraction of OEM!), but that 11-pin connector is a bugger to find ...

[4wred]

I have some knowledge of electronics,circuits,parts.Guess I could take the relay apart and try to fix it but doesn't seem worth all the effort to me.Maybe I will someday so I have a spare just want to get the thing running for now. Temps are finally getting above freezing and staying there now,getting the itch to ride!

[4wred]

Finally had time to really get into this thing,here's what I found.Hope this helps someone else having problems.
I bought a main relay and tci on ebay,tried both still had no spark.Went over all connections again and again no luck.Tested pickup coil and noticed I wasn't getting a swing on the ohm meter( thought I had already tested that before) so I bought a pickup and stator,went to install that's when I new I had a problem.The stator cover had been changed,the bike was dropped by the P.O. He put on a cover from a yzf ,had the wire hole that comes out the right side near the top.So I took out the old stator and pickup when I set the stator on the cover it wouldn't sit flat and the bolt holes didn't line up.I saw some posts on this site about yzf covers and saw that the early yzf covers pre 96 would work and the later ones wouldn't. Must have a later cover the clamp on the stator wires hit the casing when I lined up the bolt holes and only two of them lined up.So I got my cutoff wheel out and hogged some aluminum out to get the stator to sit flat on the casing,then drilled and tapped the 3rd hole.The pickup needed some minor tweaking also to get it to sit on it's location properly.Put the cover back on tried to start still no spark.Pulled cover off again looked at the pickup location in the cover and compared it to the signal tabs on the flywheel,the pickup was sitting too deep in the casing about 5mm too deep.So I put some washers under the pickup to space it out about 5mm re-installed cover and it fired up instantly!! So long story short guy's that say the newer covers won't work are sorta correct,they do work with some modification but a PITA.Much easier to just get a proper cover to begin with! Hope this helps someone else in the future.

[DonTZ125]

Not sure what was done to that cover - the YZF and FZR stator covers from all the years should PHYSICALLY interchange. The problem, of course, is that they don't WORK from one model to the other. The pickup is physically located sufficiently out of position that - while you should get spark, something else is weird there - the spark will be at the wrong time to accomplish anything.

Leaves me wondering if that really is a YZF cover. Doesn't matter, though - you must have an FZR cover for the engine & ignition to work.

[4wred]

Not sure what was done to that cover - the YZF and FZR stator covers from all the years should PHYSICALLY interchange. The problem, of course, is that they don't WORK from one model to the other. The pickup is physically located sufficiently out of position that - while you should get spark, something else is weird there - the spark will be at the wrong time to accomplish anything.

Leaves me wondering if that really is a YZF cover. Doesn't matter, though - you must have an FZR cover for the engine & ignition to work.

I will take a pic of the cover and post it when I get a chance.I guess the timing could be advanced or retarded a degree or 2 by where it sits in there.I don't have a (proper) fzr cover to compare.I'll have to get a timing light and check to make sure.And also the gap of the pickup may be larger,but it does run as I stated.I guess I could check the gap by measuring from the stator to the pickup.The bike has been sitting for 7 years and I'm sure the carbs need to be cleaned out.I'm surprised it runs and idles not too bad but is showing symptoms of dirty carbs,which I expected when I finally got it running.I will probably just get a cover from a fzr in the end,I wanted to get it running just to see if the engine was trashed.Wasn't gonna spend any more money on the bike if the engine was bad.Now I have a tci and main relay I can sell to anyone that needs one to recoup some money back.I need other parts for the bike,mostly plastics.