ER-5 No power getting to the electronics?

[ncrn]

Hey, a couple of days ago when I went to start my bike the head light and indicator lights all cut out. I found the main fuse at the starter relay had blown, I replaced the fuse and it blew again. Upon inspecting the relay I found it was no longer working correctly. I've swapped the starter relay for a new one but still when I turn the ignition there is no power?

The battery is reading 12.2v which is slightly low so I'm charging it at the moment, but I would have thought the lights would at least show dimly at that voltage?

I've checked the ignition switch and everything seems to be normal there.

Is there anything else I might be missing that might be causing no power to the bike? I've had a look at the wiring diagram and the starter relay seems to be the first point of contact to the battery, so I had assumed that replacing it with a working one would fix things?

Thanks
James
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Past: 55 Sym Jet, 91 ZZR250, 03 NSR125R. Present: 97 ER-5.
https://www.nsr125.co.uk - NSR Owners forum.

[craigT19]

well as you have found that the live is working atleast?? ( im assuming its no longer blowing fuses) go the other route and check for a dodgy earth. the earth will be on a random engine bolt... if i remember right one of the starter motor bolts is a kawasaki favourite.
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Bikes owned :- 2001 nsr125, 1999 zx6r, 2006 yzf-r1, 2009 xmax 250, 2012 yzf-r1, 2015 MT-07
Current bike : - 2016 MT-10
BCF member pops. sadly missed 1945-2003

[stinkwheel]

Check the wire running from the main fuse to the rest of the electrics (usually white as I recall). It's prone to corrosion. Try to pull it out of the snap connector that attaches to the top of the fuse holder and at the other end.

If it pulls out, there's your problem.

Also check the battery termnals are done up tight.

What about the rest of the fuses?
____________________
“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.

[ncrn]

According to the wiring diagram the earth is on the starter motor so will check that in a minute.

All of the other fuses are perfectly fine (inspected them all). I'll have a look at the wire, it disappears into the wiring loom very quickly but I know it re-appears in the head light.

Battery is definitely done up properly though.

Thanks for the advice guys, I'll go out have a look and see what I find.
____________________
Past: 55 Sym Jet, 91 ZZR250, 03 NSR125R. Present: 97 ER-5.
https://www.nsr125.co.uk - NSR Owners forum.

[ncrn]

So I've had another look, the wire stinkwheel mentioned is slightly corroded at the headlight but there is continuity through the wire from the starter relay so I'm assuming that its ok. There is no voltage that I could read at that end of the wire or coming from the starter relay..

I check the starter relay diode and it doesn't appear to be working anymore, there is no continuity either direction. It doesn't seem to be linked to the headlight etc but it is connected into the starter relay circuit so could this be whats causing the lack of power?

All the grounds seem fine and connected properly, no broken wires I could see either.

Its started hammering down with rain so I've given up till it clears up.
____________________
Past: 55 Sym Jet, 91 ZZR250, 03 NSR125R. Present: 97 ER-5.
https://www.nsr125.co.uk - NSR Owners forum.

[CarlosCBR]

Ooo watching this! Having the exact same problem with my CBR race bike, really losing patience with it at the moment too!
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https://www.youtube.com/watch?v=1OPv5mDPQ14

https://www.facebook.com/carl.simmonds.7

[ncrn]

I'll let you know what was wrong if I work it out then
____________________
Past: 55 Sym Jet, 91 ZZR250, 03 NSR125R. Present: 97 ER-5.
https://www.nsr125.co.uk - NSR Owners forum.

[stinkwheel]

I'll check later, but I vaguely recall that there might be another relay in there somewhere. There is a whole array of microrelays in the fuse box that do various unecessary tasks. Surprisingly, said fuse box can be dismantled and the appropriate relay flicked repeatedly with a fingernail until it buckles down and pulls its act together.

I'll get back to you when I have the wiring diagram in front of me because the fault you are describing has to be in a really limited number of componants in any case.

It might be worth turning the ignition on then giving the fuse box an oppertunist thump with the heel of your hand. This has worked for me in the past.
____________________
“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.

[ncrn]

I found a block of diodes near the fuse box that I pulled out to have a look at, the haynes manual calls them the "interlock diodes" they seem to be involved in sending signals from the clutch switch, side stand switch and neutral switch to the IC igniter. At either rate I tested it and they all appear to be working (massive resistance one way, little the other).

The Starter circuit relay has massive resistance in both directions which if I'm remembering right means its borked. Although it is only part of the circuit involving the starter motor which doesn't explain why the ignition won't allow the lights etc to turn on.

From what I can see on the wiring diagram voltage goes into the starter relay this then goes to the regulator, the fan fuse and the ignition main switch.

From there the voltage goes into the fuse box, which then distributes it to various switches and lights etc.

I think tomorrow I might take the fuel tank and all the plastic bits off and try follow this wire around see if its grounding anywhere.
____________________
Past: 55 Sym Jet, 91 ZZR250, 03 NSR125R. Present: 97 ER-5.
https://www.nsr125.co.uk - NSR Owners forum.

[stinkwheel]

[ncrn]

I will do that tomorrow and I'll report what I find, sounds like a good idea , I was considering doing this but without the fuse but your idea is much more sane.

Plus if I stick with this as a solution I would get some epic bodge points for my bike, it hasn't had a lot for some time .

Cheers for the advice, I really appreciate it .
____________________
Past: 55 Sym Jet, 91 ZZR250, 03 NSR125R. Present: 97 ER-5.
https://www.nsr125.co.uk - NSR Owners forum.

[stinkwheel]

[ncrn]

I think I may have discovered the problem. I tried going straight from the battery to the loom, passing the relay, sparks and the fuse goes instantly.

Before I did anything else I went back to the wiring diagram, I noted that the rectifier was on the same circuit so I disconnected it, put a new fuse in and tried again. As if by magic the lights come on so does the neutral light and the indicators etc. So my guess is that either the rectifier is to blame, or part of the loom going to it is earthing.

I'm going to have some lunch and then have a more detailed look at the rectifier. I have a feeling though that the relay I have bought is shite however...
____________________
Past: 55 Sym Jet, 91 ZZR250, 03 NSR125R. Present: 97 ER-5.
https://www.nsr125.co.uk - NSR Owners forum.

[ncrn]

I've got the rectifier/regulator off (who decided putting it over the back wheel was a good idea??). The white wire (from the relay) has some pretty horrible green corrosion all over its connectors. There doesn't seem to be any physical damage to the wires though.

I tested it according too the haynes manual and it failed that pretty badly. My guess is there is no real way to repair it so I need a new one? They are about £70 on ebay :/
____________________
Past: 55 Sym Jet, 91 ZZR250, 03 NSR125R. Present: 97 ER-5.
https://www.nsr125.co.uk - NSR Owners forum.

[Asimo]

You really don't want to replace the RR with an oem or pattern one, they all seem to die in 2 or so years. The oem kawasaki one will most likely destroy half the electrics when it dies too.

Theres a guy on the ER5 Forum who sells uprated RR's but they're not cheap, £118 posted including paypal fees. Alternatively you can save yourself £5 by registering on the forum.