having major problems. can anyone help? the bike is an 03 636. took my bike apart down to the bare frame to paint some stuff. the motor and wiring was never unhooked it just sat for about 6 weeks. put everything back together to set up as a stunt bike. wanted to turn the engine over tonight just to move the bearings but when i turned the ignition on and pushed the button it wouldnt turn over. i checked everthing i know to check but nothing. i checked the clutch swith, the kick stand swith, i even hooked up the gauge and tail light but still nothing. also checked all fuses and wiring connections and grounds. cant find anything wrong. what do i do now. when i push the start button the headlights and tailight go out like they are supposed to but it wont turn over. i tried tapping the statrer with a hammer thinking it was maybe stuck but that didnt work either. also the wiring harness from my key switch to where it plugs into the main harness gets just a little warm is this normal? so where do i go from here. is there something simple im missing or what. any suggestions would be great

 

I was having trouble with the kill switch or something with mine. I just dont use it anymore. Try push starting the bike and if it works, dont use your kill switch anymore. Mine suddenly started doing this a month ago.

 

i tried two different kill switches so what are the chances both went bad in that period of time. i talked to a buddy of mine at work and we thought of something. does anyone know if the key switch on a 636 is grounded when bolted to the top tripple clamp. i cut that part off off mine and didnt have the switch mounted. could that be my problem. im going to try to ground it tonight and see if it works. if it does ill post it on here

 

It works sometimes. Might be something internal. Im just guessing but just try to push start it.

 

the ignition doesn't need to be grounded to work

this is a dumb question i know but did you make sure your battery was charged ...

 

do you hear the fuel pump priming when you turn the key at least? cus that narrows it down a bit.

 

my dmm said 11.96 volts at the battery when i first tried it and yes the injectors primed but i didnt have the fuel pump hooked up

 

charge your battery

 

 

should turn over or at least the starter should engage. the battery voltage was alomost fully charged so thats not it. it does need charged now though. heres what i have unhooked. the headlight and fuel pump. both of which have been unhooked before and the bike has turned over then. i have the key switch relocated down by my right le. i tried ground it but that didnt work. i ran a wire straight from the positive battery terminal to the starter and it engaged and turn the motor over so its not the starter. im starting to think its a relay but does anyone know what relay it would be. there are three under the seat but i dont know which one does what. any knowledge on that would be helpful. this just boggles me that i cant figure it out. at first i thought it would be something stupid that i just forgot to hook up or check but ive been over the bike again and again and cant find anything wrong. also after i turn the key on and the fuel system does its thing i can hear a buzzing noise (not very loud) coming from the right side of the injecot rail and throttle body assembly. i dont know if thats normal ive never heard it before but like i said its not loud at all i had the key on and was looking around and had my head down close to the motor and heard it. well any suggestion still helpful at this point.thanks to everyone who has made suggestions so far

 

just start switching relays to see if you can get it to work and if it does then you know it's the relay

 

i switched the two that were the same but still nothing i dont know im stuck looks like ill have to spend some money and take it to the kawasaki dealer. that sucks

 

well if it turns over with a direct line and the relay isn't the problem then take the right hand controls off and see if you can jump the wires and get it to turn over if it does then it's the starter switch or the kill switch

 

as long as you do have all the other saftey switches checked ie tip over ,clutch ,kickstand

 

all covered i think. the tip over switch is mounted on the subframe right under the seat isnt it. ive had my kick stand switch fixed for over a year now cause it wouldntt crank with the kickstand down even if it was in neutral and with the clutch pulled

 

check your tip over sensor it has to be plugged in dont try to bypass it cause it has a computer circiut board in there that cannot be bipassed electronically. prolly your relays though get your buddies 636 and take his just to diagnose. i work at a kaw dealer, $27.99 for each relay. hope that helps.

 

yep the tip over is mounted right below the front seat if you had it off make sure its plugged in and make sure its right side up or it wont let the bike start and double check that your bypass job on the kick stand switch is still connected along with the two wires that go to the clutch

 

do you know if the relays from an 05-06 are the same as 03-04.

 

Just out of curiosity, how long did this take you? No offense, but I doubt you really did this. Have you checked your terminals within your connectors. If you were pulling your bike apart and forgot a connector, you may have pulled a terminal and not known it.

What do you mean by "turn over?" Does the starter spin, or no? If so, is it a slow crank or fast? When the term "turn over" is used this way, it is commonly meant to describe a cranking but no combustion. I see in a later post - "should turn over or at least the starter should engage," so I assume it is not CRANKING.



If it turned the motor over, you would not have a problem (unless we are diagnosing a different problem other than not running) If you have a strong crank, you can rule out your battery and starter as components, but not the wiring since you said you jumped the OEM electrical circuits. Now, I am assuming it cranks, but does not turn over? Once again - the difference between cranking and turning over.

So, without this jumper wire it does not crank at all, but with, it does but does not turn the motor over (run the motor)? Here is 1 of your problems. Sounds like you have a couple...unless it is a component disabling your starter circuit such as OMR mentioned plus/or cam/crank sensors depending on what the PCM needs to see before letting combustion happen. (I don't know - I don't have a wiring diagram)

For the love of baby Jesus, put everything back the way it was and start your diagnosis over. It sounds like you have dug a nasty grave of mess here.

We weren't there when you ripped this apart - it's hard to say. For the future, don't take apart **** you are unsure you can not fix to it's fullest. I am not trying to discourage you, but things can get overwhelming for amateurs.

This is still a possibility. As I said before, I would put the bike back to as close as you had it before and start over - clean slate. Please post back.

 

you Posted In The Wrong Area
try Help And How To!!!!!!!!!