2001 Kawasaki ER5 - crackling sound from the CDI

[matthewbyrom]

Morning all,

I was wondering if someone with more experience could advise on the following:

I have ended up with a Kawasaki ER5 (2001), which has an intermittent starting fault.

Sometimes you try & start her & you hear a faint crackling before finally the starter motor engages & the bike fires up.

You could try the starter button a few times before finally it works.

Some days it can start first time.

I've had to live with this fault for some months like this, but have had time to actually take a proper look.

Taking the seat off & having a proper listen to find out where the crackling is coming from, The crackling noise is from the CDI unit under the seat before it kicks in. Sounds to me like something is shorting out in there.

My instinct is to look for a replacement CDI, but I have heard chatter that the rectifier on the ER5 can be a weak point with these bikes & started thinking if it's a faulty rectifier instead causing the crackling from the CDI.

When I first got the bike, I noticed that all the lights that illuminate the dashboard had gone. Warning lights were OK, just the dash lights had gone.

I replaced all those, but browsing a few YouTube vids about the bike, a YouTuber commented that if the dash lights all blow, it's a sign that the rectifier is on the blink.

Now I have almost no service history with this thing, so I don't know if the rectifier has been replaced in its life & no one's bothered to replace the dash lights etc. I do know I've been running for some months like this now.

To anyone with experience of these bikes - Does any of this sound like the rectifier is the root cause of all this or am I better off going for a replacement CDI?

Thought it best to at least pose the question.

All the best.

[stinkwheel]

If it's crackling when the engine isn't running, it can only be getting battery voltage. The reg/rec doesn't have anything to regulate or rectify until the engine is spinning.

Give the terminals a good clean first, might just be an intermittant connection.

As always with an EX500 based bike, have a look at the main fuse holder and the wires leading into it which carry all the switched live supply to the whole bike, they are prone to corrosion which can extend a good way along the wire under the insulation. You'll find it on the starter solenoid.
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.

[matthewbyrom]

[WD Forte]

That age of bike could have all manner of electrical issues by now so pressing a button and expecting it all to work is somewhat naive.
CDI crackling? mmm.... I'll believe that when I see it, Show us.
it could be contacts arcing or the starter relay bouncing cos
neglect, age, 'owner improvements' etc
Do all the suggested inspect check and clean of all the electricals grounding etc plus I'd have the starter out for at least the accumulated carbon dust removal and brush check
____________________
bikers smell of wee

[stinkwheel]

A valid point. Are you sure it's the CDI and not the relay box?
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.

[Robby]

Crackling usually means a fair bit of arcing is happening. If someone was broken enough inside a CDI for that to happen, the bike wouldn't run.

I would be checking everything around the high current side. Battery cable connections, starter relay, cables to starter motor. If it's a thick wire, check that it's not loose.

A reg/rec failing so that you blow bulbs is possible, but unusual. That would be failing open, so it isn't regulating the voltage down to ~12v any more. They normally fail closed, turning into a brick.

[sickpup]

Its the starter relay.