gpz500 starting issues (sorted - now electrical?)

[Gazza M]

having some problems with my gpz500 - i have taken the fuel tank off to get to the carbs to sync them to hopefully get rid of a rattle, only now the bike won't start. stupidly i didn't check if it ran before i took the tank off. i have it rigged up as in the attached pic, can anyone spot any glaringly obvious problems with it? spark plugs seem pretty good (to my untrained eye), starter motor turns over the engine fine and the battery is fine. i haven't changed the oil yet though.

i've only done about 1000 miles on it since i got it (has ~34600 now) as it has been sitting unused since july - was going to do a pretty much full service. only i can't actually get the rocker & valve cover off to do the valve clearances as the cooling pipes are jammed in! and can't get to the airbox as the bolts holding the tank bracket are just spinning, but somehow still secured....

so tempted just to give the garage down the road a ring to pick it up, but dread to think how much this is gonna cost.

anyone got any bright ideas?
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Past: '07 YBR125, '00 GPZ500S, '99 ZRX1100, '98 CBR600 track bike, '97 ZX9R
Present: '05 R6 track bike, 140 pit bike

[jimbothe]

I would be undoing the drain screw on the carb bowls first mate to see if there is any fuel coming out. Try and catch any fuel that comes out on a clean piece of white cloth to see if there is any crap in the bowls.
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[Gazza M]

just given that a go - comes out clear. just did a check on both ht leads, they're delivering a spark nicely as the engine turns over.

it is spluttering slightly now though - i opened the throttle slightly and pressed the button, seemed to combust a little bit but doesn't read above ~200 rpm.
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Past: '07 YBR125, '00 GPZ500S, '99 ZRX1100, '98 CBR600 track bike, '97 ZX9R
Present: '05 R6 track bike, 140 pit bike

[jimbothe]

Ok, intake rubbers ok and not split or perished?

Try wire brushing the plugs lightly just in case they are fouled and not visible.

Does the fuel flow freely through the carb? When you open the drain screw, does it steadily flow through from the top?

Have you checked it's not coming out the overflow?

Two questions - why did you stop riding it and what kind of rattle are we talking about?


Going back to basics (as I can't remember) but does it have a side or centre stand kill switch? Do you have to pull in the clutch to start it?
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[Suntan Sid]

[Gazza M]

it has a microswitch on the clucth that doesnt let you start it in gear, you can start it with the sidestand down but not release the clutch in gear. discovered that the embarrassing way :p
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Past: '07 YBR125, '00 GPZ500S, '99 ZRX1100, '98 CBR600 track bike, '97 ZX9R
Present: '05 R6 track bike, 140 pit bike

[deleted111]

[Gazza M]

finally got it started, charged the battery fully then gave it a full whack, started nicely 2nd or 3rd push of the button. phew!

slight electrical problem that i thought i'd fixed cropped up again - the indicator fuse blew once before, i had a check of all the wiring when i had the tank/fairings off and it all looked ok, put it down to something shorting in the wet. put another fuse in and everything worked fine, then it did the same thing after about 10 mins of riding.

i'm thinking the battery might be off and blowing something, although surely this would blow other things than one fuse? maybe flasher relay.... i'm not wonderful on the electronics-y side of things!
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Past: '07 YBR125, '00 GPZ500S, '99 ZRX1100, '98 CBR600 track bike, '97 ZX9R
Present: '05 R6 track bike, 140 pit bike

[jimspeed]

Ok its not going to be the battery making the indicator fuse blow mate!.
have you checked that both flash when you operate them and does it only blow the fuse when you indicate one way? ie can you narrow it down to the left or right side?
could be a badly fitting bulb or maybe some wiring worn thru around the front of the bars? and rubbing when you turn the bars.

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Hyosung cruise 125(passed test on, sold) Kawasaki el 252 (better than expected but sold on) Kawasaki GPZ500S first "big"bike.(sold) ZZR600 E5..Z750 2007,ER5, currently on a 2008 Enfield bullet electra x and loving it..
,"Alpha-9: Is there any correlation between dyno rod and dyno kits?"

[Gazza M]

[Suntan Sid]

If its blowing fuses when you use the indicators, have a close look at the bulb holders in the indicator bodies.
Had a similar problem and one of the wires, soldered onto the bulb holder, had come off, it was still making contact intermittently, causing a short.
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[Gazza M]

had another look today - the indicator bulbs are both crimped at the back and soldered at the front but look fine, no sign of moisture or broken links etc that could make a short.

checked all the wiring on the back half under the fairings too - ererything seems fine, tidied up a bit of insulation that had seen better days (not on the indicator wires though). inspected the junction box too - noticed a tiny amount of moisture in one of the connections - think that may have caused a short when the bike was warm/tipped over or something. in any case, i'll take it out for a blast to check everything.

also - does anyone have any idea what the brackets in the photo are? they're welded onto the frame but nothing actually connects onto/into them....
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Past: '07 YBR125, '00 GPZ500S, '99 ZRX1100, '98 CBR600 track bike, '97 ZX9R
Present: '05 R6 track bike, 140 pit bike

[Bomberman]

Something to do with the seat fitting or a rack mount I'd guess. I'd look at mine for you if it wasn't still with insurers :p
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'89 TZR 125 - '94 GPZ500s - ZK3 GSXR600 Alstare

[psychology]

I had a similar fault on mine a couple of years back which took me ages to rectify. It was actually the main fuse under the seat which had got some moisture in and the bike would just cut out occasionally and blow random fuses. Wd40 and the problem has never re-occured. may not be the problem but worth a look.