'96 ZX-6R: Intermittent starting issues

[CRHermann]

Hey everyone,

I have a 1996 ZX-6R that has recently had some problems starting. It appears I have an electrical issue somewhere. Most times the bike starts just fine and fires up the first time I press the button. But sometimes, I will hear a click from near the battery, the instrument lights will dim slightly, and...nothing. I can turn the ignition off, try a few minutes later, and it will start fine again. It can happen when the bike is warm or cold.

I was moving along the starter circuits with my multimeter (using a Haynes manual and my rudimentary understanding of the bike's electrical components), and here's what I've noticed/checked:

• When bike does not want to start, junction box will click and nothing else happens
• Battery voltage is fine under load (when I check voltage while trying to start bike)
• All fuses are intact
• Removed junction box, tested starter circuit components within, everything seems to be fine
• It seems everything past the starter relay is fine, if the relay clicks, the starter motor rotates and the engine turns over 100% of the time

Any ideas? Thanks in advance for your help.

[earz]

I'm 98% positive you have worn starter brushes. Next time it does it, leave the key on, throw it in 2nd or 3rd gear and roll the bike backwards a few feet. This needs to be done WITHOUT pulling the clutch in. Once rolled backwards, then pit back in neutral and hit the start button. If it fires, its worn brushes. You need to pull the starter motor off and replace the brushes and clean up the armature. It's an easy job.

Let us know if the above procedure works and I'll explain the theory behind it. If it doesn't work, maybe I'm just crazy and taking a wild stab at things!!

[earz]

Bored at work, so here's some more info.

If it's brushes, the starter motor will need to be removed from the bike. This is done by simply removing the two bolts (#132) and sliding it towards the right side of the bike. The only downside is, the starter motor is bolted to the top of the engine right behind the cylinders, under the carbs. The tank may have to come off the get to the bolts.

Once the starter is removed, you will need one of each (can be ordered from any of our site sponsors):
14079-2055
21169-1058

Disassembly of the starter motor is easy, two long bolts and the thing slides apart. Replace the brushes and reassemble.


Or you can take the motor itself to any electrical motor repair shop an they can replace brushes in it. They usually just use their own brushes and reuse the stock brush holders (completely acceptable). I'm sure there are some places in COMO, but I'm not familiar enough to know where. There are a couple in JC.

Hope this helps.

[CRHermann]

Thank you! I'll try that out.

I wasn't able to replicate the problem just now in front of my apartment, but I'm sure it will decide not to start next time I'm fueling up 30 miles from home.

[earz]

Understandable. Problems never arise when you want them to.