Hey everyone Im new to the forum here and I just traded for a really nice custom 1996 zx7,but I have a problem with it,sometimes when I go to start it I just hear a click underneath the seat and it doesnt do anything,then you can turn the key off and back on and hit it and it fires up,could this be a bad starter relay or what,any help will be greatly appreciated,thanks.

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here is a list of mods.

1996 zx7 polished frame and swing arm,p.m wheels,blue anodized zx12 rotors,racetech gold springs,fox shock and spring,carbon fiber ram air tubes,blue led neon light kit,full muzzy exhaust with carbon fiber high mount can,full race replica decals,solo race shark skinz tail section,blue rk chain,2mm shaved head with 3 angle valve job,95 zx7rr crank,micro polished with counterbalances removed,Manley long rods ,Muzzy forged aluminum pistons,stock bore,cylinder walls deglazed,Muzzy adj,cam sprockets set at 105in,105ex, Muzzy adj ignition advancer set at 4 degrees,Muzzy reed block off plates(emisions removed)Muzzy 6 blade fan,qb carbon air box with kn,Vortex heat treated fron sprocket,sprocket specialist polished rear,performance machine custom wheels,Michelin soft tires,white face illumiglo gauges.

 

that thing is sweet!!!!! sounds like a relay of some sort.

 

Thanks,Im going to sell it in the spring,I'm 6'4 so its a little small for me.

 

Or even possibly the contacts in the ignition not making good contact which causes a voltage drop to the relay. Take your meter out and verify voltage to the relay.

 

Thanks for the tip,what should the voltage be to the relay,and if it was the contacts in the ignition causing the problem what is the best way to fix the problem thanks.

 

hey sspeed, i had the same issue with my bike a few eeks ago. It turned out to be one of the relay's. not necessarily gonna b ur prob, hope it helps. Btw sweeeeeet fuggin ride bro

 

hahaha, not being a smart a**, but how would 12volts sound?

edit: Start with your meter first.

 

ha.. mine does the same thing. its usually oxidation on the contacts(of a smaller relay)that supply power to the starter relay. to verify this, try holding the start button in and tapping the fuse box (under the seat) when it goes dead.. i bet she'll fire right up!

i wanna say that the relays are sealed and non-servicable. the electrical system is vastly underengineered on ours bikes unfortuanately.
in the little black box, theres 2 relays. one for the starter solenoid, and one for the headlights. if you really hate dealing with that problem, you can get replacment (preferrably solid state) relays from radioshack or an electronics supply store, an upgrade your setup. i also wanna say they're 3 or 5 amp... can't quite remember. its a dry contact, single pole, single throw (like a common light switch) relay. they're cheap to replace. also, if you ever have a short from the resistor going out in the ignition switch (gray wire...theres 2 voltages that feed the CDI) anything that shorts out with it will burn the copper "traces" on the circuit board in that block. that will leave you with power l over the bike, but no starting or running capability.

white on the ignition switch will be power in,and brown will be 12V out to the CDI and other stuff, and that gray wire will have i don't know what.. like 8 Volts or something. you can NOT jump 12V to this, just so you know.. those resistors do tend to burn up. the solder joint actually broke on mine.. i got lucky and just resoldered it... but ya, you can jump 12V to the gray. the CDI doesn't accept it.

off on a tangent again... anyway, yeppers.. the relay that controls the relay (lol)in the fuse/junction boxis almost ALWAYS the problem.

 

The guy that I got it from said he just replaced the fuse junction box,another mechanic said he thinks it is the relay beside that fuse box causing the problem.its weird you can hear the box clicking but nothing lol then you can turn the bike off and hit it again and vrrrmmm it starts up,I just want it fixed right .