Need help! Weird electrical issues! - ZX6R Forum
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post #1 of 14 Old 03-05-2019, 03:50 PM Thread Starter
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Need help! Weird electrical issues!

I have a 96 zx6r and I am having electrical issues. The bike sat for a few years and now I am trying to get it running again. I bought a new battery and when I hit the starter, the starter relay just clicks, nothing else happens. I have tested the fuel pump hooked directly to battery and it works. If I unhook the fuel pump the starter will turn over and it will run off a fuel bottle. I have also replaced the starter relay and fuel pump relay. Trying to start the bike in neutral and with kickstand switch bypassed. Any help would be appreciated! Thank you!
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post #2 of 14 Old 03-05-2019, 04:21 PM
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Take the cables off the starter, and the starter relay. Clean up the metallic contact areas, so there is no corrosion. Do the same with the negative battery cable, at both ends. The frame connection in particular.

Great everything you take apart, with dielectric grease so it doesn't corrode again.

"Basic stuff fellas. Use your head for something other than to break your next fall."
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post #3 of 14 Old 03-05-2019, 04:24 PM Thread Starter
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Take the cables off the starter, and the starter relay. Clean up the metallic contact areas, so there is no corrosion. Do the same with the negative battery cable, at both ends. The frame connection in particular.

Great everything you take apart, with dielectric grease so it doesn't corrode again.
I’ll give that a try!
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post #4 of 14 Old 03-05-2019, 04:33 PM
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I'm assuming you don't have a multimeter?

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post #5 of 14 Old 03-05-2019, 05:41 PM Thread Starter
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I'm assuming you don't have a multimeter?
Yes I have a multimeter.
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post #6 of 14 Old 03-05-2019, 05:41 PM Thread Starter
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Cleaning all termanals didn’t fix anything.
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post #7 of 14 Old 03-05-2019, 05:43 PM Thread Starter
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It’s weird if I unplug either the fuel pump or the fuel pump relay it will fire but not with both plugged in.
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post #8 of 14 Old 03-05-2019, 06:12 PM
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So the problem is likely common to both. If the path for current to flow is not open (you just reduced the odds of that), the next most likely problem is a short circuit.

When you unplug the pump or pump relay, you open the path the short is on.

I'd expect that the pump has an issue..... The relay feeds the pump, right? With the pump disconnected, you have the problem, if the relay is still connected?

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post #9 of 14 Old 03-06-2019, 10:33 AM Thread Starter
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So the problem is likely common to both. If the path for current to flow is not open (you just reduced the odds of that), the next most likely problem is a short circuit.

When you unplug the pump or pump relay, you open the path the short is on.

I'd expect that the pump has an issue..... The relay feeds the pump, right? With the pump disconnected, you have the problem, if the relay is still connected?
If the pump is disconnected engine turns over with relay plugged in, if I disconnect the relay the engine turns over with pump plugged in, pump doesn’t make a noise
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post #10 of 14 Old 03-06-2019, 01:46 PM Thread Starter
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Well the new fuel pump helped but still not starting every time I hit the starter, and now it looks like I’ll have to rebuild the carbs since there is a nice puddle of Sunoco 112 on the floor.
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post #11 of 14 Old 03-07-2019, 06:04 AM
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^ not weird and not surprised on either/any issues....... that is what happens when you let them sit for a few years ?!

Sounds like you have more work to do and you will eventually be able to enjoy riding it


What else is old and crusty and needs attention!!!!!!!!!!!!
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Stupid people say stupid things on the internet, so be wary of who those people are. If you solicit advice on the internet, just keep in mind 99% of what you'll receive is not based on fact or science-and likely atleast 95% of it is based on bullshit and bravado regurgitated from some other schlub who also did not experience any of what they claim and are also full of shit. If you don't like my bluntness- too bad. I am not here to please you, so move along, your approval is not desired nor is it needed. So before opening your pie hole and adding more stupidity, perhaps sit back, listen, absorb and learn something. You know that saying, it is better to remain silent and thought a fool than to open your mouth and remove all doubt!
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post #12 of 14 Old 03-07-2019, 12:38 PM Thread Starter
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Ok here is the latest, it depends on what the fuel pump case comes in contact with if it will start, if it touches metal ( like frame ) it will start.I’m assuming it is a ground issue somewhere.
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post #13 of 14 Old 03-07-2019, 02:49 PM
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Fuel filter been changed? There could be some cloggage in the filter. I think they go for 9 buckaroos. Might be worth a shot if you are still scratching your head.

“If a man does not have sauce, then he is lost. But the same man can get lost in the sauce.”
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post #14 of 14 Old 03-07-2019, 04:16 PM
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Sounds like you just found the problem, the ground path for the fuel pump is not complete. If you have the wiring diagram see if you can figure out how it is supposed to be grounded and check that connection.
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