kle500 non start
 

i have a kle500a1 and its just died on me . on pressing the starter button all lights went out . have mannaged to get the lights back on but on pressing the start button all i get is a clicking from the junction box . has a new solinoid and the starter is ok . battery fully charged . even bridging the solinoid i get nothing . any one come across this before . i am thinking bad wiring to start with . thanks in advance

Or bad connection.....??

Bad connection is most likely. And probably on the large draw/load starter motor circuit.

Look at the largest wires leading away from the battery (both positive and negative terminals). Check that the wires are firmly attached by pulling on them .. any movement is a poor connection. Continue along the length of these wires untill they stop, if they connect to another large wire - test that too. And the next large wire. Eventually the wire will stop (terminate) on some large component - the negative wire usually on the motor, the positive wire on the solenoid/starter motor.

kle500 non start
 

OK thanks for advise gonna have a look at the weekend let u know how I get on

kle500 non start
 

well this bike is now doing my head in . have changed the battery . starter solenoid complete loom and both earth and live feed to battery and motor .when I switch on the ignition the oil light and neutral light are dim then all of a sudden the go bright !! , on pressing the horn all lights go out !! just cant work this out all I am getting is just a clicking from junction box :(

Do you have an electical Multimeter ??

What's the voltage at the starter motor possitive terminal when you press the starter button ? The cable should run directly to your starter relay box.

Earth the Neg. terminal on meter to the frame.

If you're getting more than 12V then your motor might be jammed. Give it a whack.

If nothing, remove the motor and jump it directly to a good battery and see if it spins.


If you're not getting good voltage to the motor then check all terminals. Check the voltage on the other side of the relay and see what it is when you press the starter.

Check the safety switches too. These can disable the starter motor but generally the relays don't click in this case.

If everything works out you might have a massive voltage drop somewhere. You can check this by doing a voltage drop test.

non start kle500
 

starter motor is ok . soliniod ok ( used one of other bike thats good ) battery good . have 12v to solinoid on both wires . no voltage to starter motor from cable . tryed jumping the solinoid still nothing

No voltage at your starter motor is the problem....

You need to check continuity from the starter motor all the way back to the solenoid (where you do get voltage).

non start kle500
 

well I think the solenoid may have blow as getting 12v on both red wire (switching 12v ) and white wire (constant 12v )where it plugs into the solenoid , but getting nothing on motor side of solenoid

Common faults... As long as everything else is wired up properly.

non start kle500
 

well no further faward . still no feed to starter motor . even with a new solinoid . still just clicking at the junction box could it be the starter button even though when pressing it it clicks the juntion box .
just to recap it hade new loom new solinoid (twice) all high tention cables replaced have checked all grounds and battery all ok

Check the starter motor earth. If the motor isn't earthed then it won't draw a current.


Also ( I had this on a customers bike recently), make sure that the cable running to the terminal on the starter motor is ONLY touching the terminal on the starter motor. Check the nut on the starter and make sure you have the insulating washer between the cable and the terminal.

If the cable is touching the starter motor body then it's just short circuiting. This will make your relay click also.

non start kle500
 

ok mate i will try to check tonight . i did have a look last night but it was strange i switched the ignition on and the lights came on and went out then came back on slowly

That sounds like a 'Parasitic draw' from your battery when you turn on your ignition.

Which would back up the theory that your starter cable is earthing out on the frame or starter.

You could also bench test your starter motor by removing it and using jump leads.

If your starter is jammed it would also cause this problem you're having.

Sometimes a piece of wood and a hammer can fix a stuck starter motor.

no start kle500
 

well checked the cables all ok starter all ok tryed jump leads as well still nothing just clicks at the junction box . still no feed from solinoid to starter . make me think could be the ignition switch or starter switch . so frustrating at the moment