South West Bikers | Motorcycle Forum

Engine kill switch or electrical short/open circuit?

If it's any help. I spent 2 days looking for an intermittant electrical fault on my zx7r. All the lights worked, but starter would'n turnover, could'nt hear the 'click' when the starter was pressed so thought it was the solenoid(starter relay). Managed to get the starter turning by connecting the battery direct to solenoid but it still would'nt fire up. In the end I went round all the connectors and found a broken wire at the clutch switch (effectively this works like the engine kill switch when you try and start the bike in gear without the clutch held in). No power was getting through to the starter circuit or the ignition coils.

if the "Big wheel with a big magnet" is the fly wheel then thats it, yes the starter dose link in to it.

i have no problems with the Clutch.

the problem with the fly wheel is it turns and gets stuck at a certain point and will not turn again unless i move it by hand which is hard and that was without the clutch engaged and no chain on the bike with it sat in neutral

so i can only think there is a problem with the gearbox

Must be mate, nothing else.

i have spoken to Crescent Suzuki in detail about my bike and it seems there is a broken crank or crank case or something just as bad.

there for it needs a full engine rebuild i have taken the engine out and am attempting to do the engine rebuild myself as i have'nt got £500 - £600 to pay for a rebuild so please wish me luck as i am going to need it

If you ever need a any help/assistance/making cups of tea just send me a PM. I have no technical knowledge whatsoever though.

There was an RG 125 engine on eBay the other day.

Good luck with the rebuild mate

ya this one but i am unsure if it's the same insides as mine

E-bay Bottom end

i did on the bottom end from E-bay and won total cost £15 so i am praying the bits i need are the same and all will be fine i hope.

Hopefully it's the same, what year is yours? Must be possible to find out on the net womehow, good luck with it, if i could help/had any time off work i would love to lend a hand.

the bottom end from E-bay is a 1990 and mine is a 1993 so i am hope the inside / Guts are the same

i have'nt cracked the engine in half yet but i have pulled some metal bits out of the barrle heres a pic of what i have pulled out so of

How are you getting on with this mate?

well I got a tax rebate today for £685 so i am cashing it and taking the engine to Black Dragon so he can do a full rebuild and fix and problems that may be there

Sounds good.

the engine in now in Black Dragon and i have been told that the "Main Bearing is [Censored] so it need a main bearing crank and everything else
so i am off the road for 3 or 4 more weeks