Once again

[Bratman3401]

Okay so i posted the not stating topic and alot of people tryed to help me out and i tryed everything and now im outta ideas i painted my engine and frame after i have the bike running and now it wont run.

so thought it was a ground issue makes sence right nopppppe i sanded down all the spots the ground to the frame on the frame and engine and nope still wont start i tryed a different starter that didnt work i tryed everything. i pulled the engine out again put it in my running fzr frame the unpainted one still doesnt work same prob keeps happening.


For anyone who didnt read the other thread once everything is hooked up and i go to start it nothing it clicks at the relay.

So for a full break down i turn the key on all the accesories go on lights fuel pump all of it

then with the right thumb switch on start and yes it works and is good i go to hit the start button and as soon as i do all the accesories go off and the oil light goes on along with the neutral light that was on the whole time the neutral light is the only thing that stays on thru the whole thing

so i really hope im not this stupid cuz i think i remember filling it with oil but sence it is the oil light that goes on would there be a chance that maybe it needs oil? just curious would that stop the bike from even turning the starter?

when i painted it i just covered the holes with tape and sprayed away would covering the oil thing at the bottom or anything with paint be a prob?

okay sorry for all the writing but man i am so frustrated i wanna just sell the bike and buy a new one but i would at least like to have it rideable before i get rid of it so thanks and any comments are welcome

i dont care if it a far off guess it is better then nothing

[manveru]

this is going to sound crazy, and i'm not up to speed on your other thread, but sometimes my bike does something similar a couple times a year. I put it in high gear and start pushing then drop the clutch, almost like push starting it. It frees something up, and then i try and start it and it turns right over. not sure what it is since its only happened a few times in a few years.

[Bratman3401]

k thanks i will try that tomorrow and see what happens

[cad600]

If Manveru suggestion does not work, then I really think it is something simple with the electrical system.

The oil light coming on with all the other lights going out when you hit the starter button is normal. If the lights don't come back on when you let go of the button then you have issues that stem from the starter switch. I know you removed the entire electrical system from one running bike to this and still have the same problem, but

1) did you change everything including every little switch and button?

2) did you disconnect any of the components when you switched everything?

Basically, I would start looking at every switch that was left on the bike and see if they are passing current properly.

Also look at every wire connector and make sure they are connected to the correct terminal. Most of them are color coded so it should be simple.

But I do know of someone who plugged the fuel pump into the rear brake switch. So every time he hit the rear brake, it would pop the fuel pump fuse.

[Dragon]

I say if the above mentioned things don't work out for ya, take a mallet or something and tap on your starter. Then try it again. Had a problem like this before, and it turned out to be the starter was taking a dump on me....

[yamaha_george]

Hi,
some one help me out here :-
The starter button completes the circuit when pressed by shorting down to the handle bar as earth ?

I ask because since he painted I am wondering if there is sufficient connection to make the circuit complete with the junctin between bars and the fork / frame?

[Bratman3401]

just to make this clear when i push the start button all the lights turn off except the neutral and then the oil comes on so when the button is pushed the oil and neutral lights are glowing and everything else is off and when i let go the oil light goes off but the neutral light stays on and everything else comes back on.
I doubt it is the starter i have tryed 3 and i switched all the electrical but the wires on the engine and i am pretty sure that they are good cuz i did alot of wire matching when i had both bikes next to each other

[Bratman3401]

okay just so its clear it cant be the frame i switched the engine to another frame that is grounded out and not painted and it dies it but now when i try it if i hold the start button the starter relay doesnt just click once it clicks repetitively

[Bratman3401]

okay so i got the bike to turn over. It will only spin over when the covers arnt on. i take the peanut cover off and it spins as soon as i put it back on it stops. it will still spin as long as it isnt tightened if its loose enought to wiggle then it will spin wierdest thing. and now my battery is dead and i have no charger so tomorrow i will pull out the jumper cables

[cad600]

Hang on there a minute. You have something wrong with that cover if that is happening. Check out the cover and make sure everything looks ok, like not missing chunks of metal... because it sounds like something is binding up on you. Did you install a new cover recently? Were / Who did you get it from? Also, did you lay the bike over when you pull the cover off? Oil would have come out of it if the bike was standing up on the stand and you pulled the cover off. Check and make sure there is oil in the thing.

[Bratman3401]

It does not have that much oil in it if any i just wanting to hear it spin once before i went on with my project and yes the cover took a dump i had it on my bike when i went down it has cracks that i repaired but i guess it dented it in or something so now i need another one. so now i will try the cover from my other engine and get it running when i go and get some oil so my next question is when the bike was wrecked i busted up the flywheel or the thing that spins inside the left cover. it has a spot in it where a piece of metal was ripped off and it has an indent in it. what do i do about this i have another one but not all the things required to replace it will it still do its job like it is or does it have to be perfect? all the magnets are still in place. and if i am going to replace this will it be worth it spending the extra money and while its off go and buy a ignition advancing kit? i did the ghetto way in the wiki and it made a noticable difference so does this kit do the same idea and how easy is it?

[cad600]

That has got to be your problem. Those covers are very thin and almost always destroy themselves when the bike goes down. Just make sure you use a new gasket on that side since oil does go through that area. Also check the gears inside the cover and for dirt and metal that may have made its way into the engine cases.

Can you put up a picture of the cover and the area of the engine that is affected for the stator cover? That side stays dry, so as long as things line up it is not too big of a problem to have a dent or hole. I had a hole in the engine cases on my FZR engine at the stator cover and the bike ran fine. You would want to be careful about riding in the rain though as you don't want water to get in there. But if the stator itself is damaged, you probably want to replace it. Also, if the flywheel is damaged you will need to replace it. Make sure you get one for a FZR as the YZF600 flywheel does not fit and uses different timing marks.

[Bratman3401]

yea it is the thing inside the cover i guess it is either the flywheel or the stator and i have an fzr one i just dont have the tools to take it off right now. i have tryed to crack it with hand tools but i cant get it so i guess i will have to wait on that and yes i will get pics a little later when i can pull it out of the garage my camera phone needs alot of light to get things to show up thanks for the help im so much happier now that the engine at least spins.

[Bratman3401]

and btw u have done the yzf engine swap what are the differences on the engines that made u swap? does it have more power or something and do u need to replace the whole harness and all the electrical items?

[cad600]

You need a flywheel puller. It is a weird size so you may not find one at the local automotive store. You can get one from www.motionpro.com Look in the too section and you should be able to find one.

The YZF600 engine is about 10hp more. It is a direct bolt on into the FZR. But yes, you do need the full wire harness, CDI, radiator, and carbs. The radiator needs some simple brackets to hold it in place, but they are really simple. Other than the HP, there is no real advantage to the engine. The only real problem is the air box. You will need a 95-96 YZF600 air box no matter which year model engine you get in order to avoid the ram air issue. You also need to use a YZF gas tank so the air box would fit, but the box still needs to be cut down to fit into the frame. It sounds bad, but it really isn't. It can all be done in about a day.