Kawasaki ER5 won't start

[tomaha]

First of all - hi there, to all you bikers out there. I've decided to post my problem here, as you seem to be serious about sorting others problems, which I cannot say about forums in Poland.

Anyway, the case is not obvious. I've got a 2000 Kawasaki ER5, which I'm really attached to and I don't consider getting rid of it. I've got various problems with it over last years, but more or less, the bike was in working condition. I've had some problems with the starter not being able to take a full turn, but that has been solved. Yet another issue had surfaced.

When I press the starter button, there comes a series of random clicks from the relay on the right side of the battery. It's quite random with no distinguishable pattern of clicks and silence. It's accompanied by no, or very limited starter movement, and an overflow of gasoline coming out of the engine block. When i hold the button over 3 seconds, the insulation on the wiring starts to melt and burn. The spark plugs are quite new, with no more than 500 km of use.

All in all, the bike is resistant to do anything aside from burning itself and spurting gasoline, which leads to a dangerous combo. I'd be glad for any help you can provide me with.

Cheers

[MarJay]

Sounds like the starter solenoid is at fault. Apparently you can bridge it with a screwdriver to override it temporarily on some models. I'm not sure about the ER5, but it seems likely.

If you've got fuel overflowing, clicking and hot wiring, I'd say that a starter solenoid problem seems a likely culprit. The starting process pumps fuel into the carbs, but because the solenoid is not engaging the starter motor is not turning. I'm guessing that the solenoid not fully engaging puts load on the wiring causing the burning you mentioned.
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[Suntan Sid]

A friend of mine, with the same bike, had similar problems.
Not so much the electrical side, but difficulty starting, and massive fuel overflow, when trying to start.
The fuel problem was eventually solved with many, very, thorough inspections and cleaning of the carbs.
There was a tiny split in one of the carb diaphragms, just where the lip of the diaphragm fits into the groove on the carb body, very difficult to spot.
This was leading to excess fuel getting into the engine oil and the air box, via the crankcase breather.
Check your engine oil for petrol contamination!
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[Val]

[bikenut]

from where exactly does the fuel come from....an overflow form the carb or elsewhere.....you know of cmnsl which will be of benefit to you....there may also be a manual on here.......

the clicking is probably a bad connection on the starter relay or solenoid ( same just a different name ) , battery, stater motor connection or even a earth bad connection.

the lead getting hot and burning is an other issue, may be a bad connection.......are you sure you sorted the starter motor properly or is there a short circuit inside it......?

are you sure the engine cylinder is not filling full or fuel and causing a hydraulic lock??????

on the next try, with no success, remove the spark plug and kill the ign...turn engine over by hand or put in gear and push the bike....does liquid fuel come put the plug hole.......if engine overchoked, the plug will be wet/black and no liquid fuel ( or very little liquid ) will be present....but if liquid fuel is present then maybe the engine is flooding.........how is the air filter.
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[davebike]

Sounds like the classic er5 Hydro-lock
Carbs flood into engine engine will not turn
Wiring gets hot etc etc

Pull the plugs and try to spin motor
I bet it turns just fine but you get a shower of fuel !!

Oil level will be very high fuel in oil

You probable got a stuck vacume tap
and sticky float valves
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Dave
NC750Xdct + others at work !
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[misscrabstick]

I agree with Dave, carb issue is causing an engine full of fuel and hydraulic locking to the extent that the starter can not compress it and rotate the engine, perhaps the float needles, seats and o rings need looking at?

[davebike]

My experience with several ER5's with the problem is it is mainly the tap sticking sort that and they work

I resorted to an in line manual tap a few times the repair kits don't fix the tap for long and taps are either ££££ or in as bad nick
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Dave
NC750Xdct + others at work !
davebike1@gmail.com