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Old 06-29-2011, 10:19 PM   #1
TexasPsyclone
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Angry No Juice!!!

So I'm rollin down the road - got my girl at my side. Nice evening ride out to play some softball, no big deal. As I lean into a nice turn and roll on the throttle, suddenly - SILENCE. WTH?? No guages... no lights... no tach... it was like someone hit me with my own personal EMP. So I coast into a handy parking lot and pop the seats. Start looking for the obvious - blown fuses, burnt wires, loose connections... everything looks fine. There's a guy working on the building I ended up in front of who happens to have a volt meter - battery is sitting at 13.3v and the connections are tight. ground is tight. I'm near Grinchy's pad, so I ring him on the phone and he shows up and we start pullin on wires, looking at every fuse, searching for any clue... Everything looks as it should.

I get Scott from Motorcycles Unlimited on the phone and he verifies the location of the main fuse and leads me up towards the ignition switch. (This dude's knowledge of a wide variety of bikes is impressive - especially off the top of his head!) Between Mike and I pullin on wires, I see the neutral and oil pressure lights flicker. Getting close....

I reach up behind the ignition switch housing and bingo. Shove the wire bundle closer to the switch housing and lights come on. Pull it away and they're off. So it looks like wires up in the switch have either chaffed through or unsoldered themselves. (From reading on the ZX Forums, this is not uncommon) So the question now is do I try to improve what I have or attempt the switch replacement (which the factory has gone to great lengths to keep from being a simple task).

Just want to say a big thanks to Mike (Grinchy) for dropping everything and coming driving out to help me on the side of the road.

Also - thanks Scott for leading me to the problem over the cell phone. Amazing. I would have thought you were sitting there reading from the maintenance manual.

Glad this didn't happen a few days ago while Leah and I were out on the 3 Sisters. It was only 108 degrees!
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Old 06-29-2011, 10:41 PM   #2
da1hobo
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Had a similar experience on my CL125 back when I first started riding. Hit a nasty bump on a trail and everything just died. Pushed it all the way home because I was a kid and didn't know how to fix it.
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Old 06-29-2011, 11:02 PM   #3
Squanto84
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Nicely written, Glad I was able to help! Sound like a new key switch is in youre future. We probably have one off of that ninja 500, if it would fit. Glad to hear it happened at a somewhat ' convenient' area.
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Old 06-29-2011, 11:26 PM   #4
TexasPsyclone
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87 HD FXLR (Gave her up)
03 ZX7R
94 HD FXLR
Cannondale R600 & Killer V900 (1HP....thats Human Power)






I wonder if the high charging volts have anything to do with the connection failure at the switch. It would suck to replace it and have the new one fail for the same reason.
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Old 06-29-2011, 11:31 PM   #5
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Just happened with my son about 2 hours ago- like 9:30 Wed. night. We messed up a relay when we were re-bundling the wires and had to get a new one. He plugged it in and away he went. About 9:30 on the way home . . . . . . .shhhhhhh - no gages or anything. Starter runs, brake lightes work, exactly the same thing. Seems like the ignition relay is TU again. Don't know what's causing it to do this. David (1HEALTHY750) let me borrow his truck and go pick it up. Thanks David. I HATE ELECTRICAL PROBLEMS so I can sympathize when you're sitting on the side of the road. I get foot stompin frustrated.
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Old 06-30-2011, 07:24 AM   #6
cedestech
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I had the same problem with a Dnepr ignition switch.... of corse it was made by drunken Ukranians so upgrade was 100% better then "factory"....

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Old 06-30-2011, 11:02 PM   #7
whiz kid
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I had a similar incident once. 1st day learning to ride b4 I too the MSF course.

Riding down my street the bike suddenly lost power, I'm coasting down the street revving the throttle trying to get it to do something. In my head I'm thinking WTF I just bought this thing.
Pulled onto the sidewalk to check it out.................... I had accidentally bumped the kill switch
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