89 ZX7 H1 Will Not Crank - ZX Forums
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post #1 of 10 (permalink) Old 03-28-2019, 08:06 AM Thread Starter
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89 ZX7 H1 Will Not Crank

My 89 ZX7 H1 will not crank. I have had this bike for years, It has not seen the road since I did a frame up restoration. I started it 2 years ago without an issue. I put a new battery in it and now it will not crank.

I DO get lights on the dash. Oil and Neutral, when I put it in gear the Neutral light goes out so I assume the Neutrals switch works.
When I Jump across the starter relay connections (the larger ones) it WILL CRANK the starter.
The Off/Run switch has been check and is working per the OHM readings.
The Start Button has been check and is working per the OHM readings.
The KickStand switch has been bypassed (No difference) and I also verified that the KickStand switch is working per the OHM readings.
All Ground Connections have been cleaned and check with OHM meter.
Just about every connector has been pulled apart, cleaned and lubed with dielectric grease.
I have tested the starter relay with this test and it checks good.

I am at a loss. Anyone got any ideas?
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post #2 of 10 (permalink) Old 03-28-2019, 08:25 AM
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Junction box has a relay inside it that can get corroded.
Does it click?

May take many clicks to make a slight clean contact to start.

If jumping across relay cranks, maybe put an inline push button to start just to run it.

Just a thought

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1998 ZX7R - Endurance body, named Frenchie
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post #3 of 10 (permalink) Old 03-28-2019, 08:43 AM Thread Starter
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No Clicking in the Junction Box. Only way I can see to open it up is to drill out the rivets.
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post #4 of 10 (permalink) Old 03-28-2019, 08:48 AM
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Tap on the box while u hit start button.
See what happens.

Other than that I'd do a temp start button to get running.



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1998 ZX7R - Endurance body, named Frenchie
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post #5 of 10 (permalink) Old 03-28-2019, 10:23 AM
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Have you looked at the sticky called 'My ZX7 don't start' in the ZX7 sub-forum?
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post #6 of 10 (permalink) Old 03-28-2019, 11:04 AM Thread Starter
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Yes I have and thanks for making that post it was a big help.

Grey wire having just under 6 volts - Can't seem to find a "Grey Wire" on the H1
All grounds clean and tight (engine, frame behind fuel pump, subframe, water pump, harness to battery) - Yep
Jump the kickstand switch by unplugging and putting the two ends together - Yep
Make a jumper wire and plug in to the outside two plugs of the left control on the harness side (unplug from left control and jump) - Not sure what is meant here
Open and clean the kill switch bar control - Done and Verified with OHM Meter that it is working
Make sure the fuel pump relay is plugged in well - Done Fuel Pump Relay was replaced 2 years go along with Fuel Pump
Remove all wires from the starter relay and clean them -Done Many times
Check/clean the power wire going to the starter - Did NOT but the Starter Cranks by jumping the starter Relay
Make sure the neutral switch wire is clean and tight - Done and the Light Functions on Dash as it should so I assume it is working
Make sure the ignition pickup connector is tight - All electrical connections have been checked
Check the connector to the alternator is not melted, corroded, etc. This happens often. - NOT DONE but would this keep it from cranking?
Take the handle of a screwdriver and smack the starter solenoid and junction box. The relays inside get stuck from time to time. - Done and even have another relay so it's not the problem
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post #7 of 10 (permalink) Old 03-28-2019, 11:12 AM
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What is meant in that point is to bypass the clutch switch in the left side controls. Small micro switch at the base of the clutch lever.
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post #8 of 10 (permalink) Old 03-29-2019, 08:36 AM Thread Starter
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No luck bypassing the clutch switch. Will probably try to take the junction box apart this weekend to see whats happening inside. Other than that I am stumped...
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post #9 of 10 (permalink) Old 03-29-2019, 05:35 PM
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Try a trick first. Disconnect the fuel pump relay and try to start it. Let us know the results.
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post #10 of 10 (permalink) Old 03-30-2019, 01:26 PM Thread Starter
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Got it cranking. After testing just about everything it ended up being dirty contacts in the ignition switch. All cranking now. Just need to put some fuel in it and see what the next problem is. Thanks to all for the help.
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