So I bought this 88 Ninja ZX600R for real cheap but it doesn't turn over, the guy said all it needs is a junction box, and I took my mechanic with me and he said it looked like everything checked out on it for the most part.

My first question is that with everything setup right to start (kickstand down, key turned, etc) the only thing that happens is the junction box makes a click. Is there anything that will cause this other than a fried junction box? Also the starter and solenoid are new.

And my second question. The guy re-jetted the carbs by himself and also gutted the exhaust but he either did both at the same time or jetted the carbs so that too much gas flows either way it runs too rich with all four air filters so he only put two on them. If I understand the engine correctly, If I put an actual muffler on this thing not as much air will flow out and it will actually have some back pressure and make it run leaner correct? Or will it have to have actual oxygen increased and not exhaust back up?

Any help is extremely appreciated.

 

Welcome, GTman! I'd suggest checking your ground circuit regarding your "click." Sounds like you're getting a voltage dump somewhere. If that checks out, try your key switch. As for the carbs, pull them and see what main-jets are in there. Drop down a few sizes. Might double-check your float height while you're at it. Keep all 4 air filters (pods?) on your carbs. One speck of crap can ruin your day and your hard parts. I won't ask if the exhaust is within reasonable db.....tell me it is.
Welcome, again. Post a pic or three!

 

Thanks for the welcome and quick reply. The ground circuit is the ground wire to the engine block correct? I already pulled it off and scraped the paint under the connection to be safe but I didn't check it with my meter. Whats left of the electronics (head, tail, and brake lights) still work so I'm pretty sure I'm getting ground to everything. And is it really that easy to rejet the carbs? As for the exhaust... it's without a doubt going to be loud and annoying. It's essentially a straight pipe. He also stripped all the fairings off of the thing.

Oh and when you say voltage dump do you mean its dropping or shorting to ground?

 

Here she is in all her inglory.



Except for the fairings she came with everything a 15 year old white trash kid could want...

A gutted muffler to make an extra 40 HP and be extra loud of course. *sarcasm*


And even a sweet custom paint job.


UPDATE: After all the power sports places being closed today I decided to open up that junction box and research more into what it actually is, it's a starter relay circuit. So I'm thinking I do have a bad connection somewhere down the line. If all else fails it is the relay that's bad and I'll test it. but jumping the starter solenoid yields nothing so I'm assuming it's a connection problem.

 

The starter relay is weak on this ride.

If I remember correctly, whitey(jimmy)made a comment on just that a yr or so ago and also on the valve tuning causing hard starts.

 

If I'm following all the wires correctly the relays in the junction box are switched on when the kickstand and ect are in the right position they enable the relay then the starter switch triggers the relay, the relay throws voltage to the solenoid and it goes to the starter correct? But also I've jumped the solenoid and gotten nothing from the starter but my battery is probably dead.

I just jumped a wire from the battery to the solenoid switch and it lifts the solenoid but doesn't turn.

It also has a new starter.

New update. I tried jumping it off my car. I tried using the start button nothing but the relay clicked. Hotwired the solenoid switch wire to the battery and all it did was click. I hotwired the solenoid so I should have had a straight connection to the starter and I still got nothing. I have no idea whats up with it now other than maybe the starter cable is loose.

 

Major update. Today me and my mechanic friend were working on it and we jump my car battery straight to the motorcycle starter and nothing. Sooo the engine was locked up. He popped the spark plugs out and sprayed WD-40 into the cylinders and then hit the starter and prayed.

Lo and behold it turned over. we put the spark plugs and everything back and kept trying to start it and it fires and turns really well only one problem the starter doesn't grab the engine 100% of the time. It makes a grinding and spinning noise so do I need a new starter now or is there another assembly that will cause this?

 

pg 8-15 of the fsm concerning the Starter Motor Clutch


I remember responding to this question on another forum. Thought I recognized the ride. My recommendation is still the same. Welcome to KF and good luck with the troubleshooting.

 

Nope this is only on one other forum and I didn't post pictures on the other one nor gotten a single response which I'm very grateful you guys are helping me so thanks. But I'm about to pull the starter and try it out of the engine to check if its the starter or clutch. To replace the clutch requires an engine tear down right? Any idea how expensive a clutch will be?

Thanks again for all the help.

Also any good way to test the starter and clutch?

Also do you have a digital or hard copy of the FSM?