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New to the moto world, inherited a Kat

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  • New to the moto world, inherited a Kat

    Good Morning, Afternoon or Evening fellow Katriders

    So first things first, my name is Keith and as the title of this thread suggests I'm new to motorcycles and I have inherited a 98 600f. It's kind of a long story but a lady friend said if I could get the bike running i could keep it. Having no experience with motorcycles doesn't make me a total weenie, I have been a mechanic with Mercedes Benz for the last 10 years and I am no stranger to hack jobs and wanna be custom tuners.

    More about the bike, she bought the bike non running because she was convinced she could fix it, after sitting for a year plus god knows how long it's my problem now. The story goes she bought it from a friend of a friend who tried making it a race bike needless to say they fell short of that goal and got rid of it. The bike was laid down and the fairings are more or less junk but the frame made it out unscathed. The wiring is a nightmare with cut wires and loose connectors that lead nowhere. I will be uploading pictures tomorrow so you guys will be able to see more clearly.

    What I've done thus far, carb rebuild/ cleaning/ bench synch (thanks to video thread carb 102), new fuel lines+ filter, spark plugs only because the wires looked really good, oil+filter, air filter+cleaned box, hose clamps on all rubber hoses. Pretty basic tune up type of stuff.

    Now the problem is a no start, no power at the plugs and no power to the coils, on a Mercedes I can just pull up a wiring diagram and break out my meter no problem but so far I can't seem to find the right information. Also since the history of the bike is shady I'm wondering if somebody tried to hotwire it, in an ignition thread I read about a safety feature for anti theft. I have power, the lights come on, voltage at the battery is good 12.9. The starter cranked when I power it directly, and the starter relay gives an audible click when power is directly applied so I can comfortably narrow it down to ignition or cut off switch problem.

    Can any of my new friends point me in any direction or post a writing diagram, words of encouragement I'll take anything to be honest.

  • #2
    Clutch safety switch, jump them together and try again. Check the fuses, check for power at the CDI. You can download a manual from the wiki above.
    "I'm sorry, I didn't mean to upset you when I called you stupid. I thought you already knew..."
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    • #3
      If the wiring harness is really hacked up, I would suggest...





      If you think it's fixable, then check the wiki link, search manuals, download it for free.


      Does the bike have an OEM ignition switch? If not, then your correct it will not run. Not going into specifics, but in the switch is a design feature that will prevent the Ignition Control Module from firing the coils if it's missing or been tampered with. A replacement switch is the simple answer there. Tumblers (if you still have a good one) can easily be swapped around for key matching.


      There are also 2 safety switches to be aware of. A clutch switch that prevents the starter from turning over unless the clutch is pulled in. A kickstand switch that will kill the engine and prevent the starter from turning over if the bike is in gear and the kickstand is down. Associated with the kickstand switch, make sure the neutral sensor/light is functioning correctly.


      Krey
      93 750 Kat



      Modified Swingarm, 5.5 GSXR Rear with 180/55 and 520 Chain, 750 to 600 Tail conversion, more to come. Long Term Project build thread http://katriders.com/vb/showthread.php?t=96736

      "I've done this a thousand times before. What could possibly go wron.... Ooops!"

      Comment


      • #4
        My bike was bought as a theft recovery. My ignition switch was missing completely and ignition harness was cut up. I used a generic key switch from Advanced Auto, not gonna go into specifics on bypassing anti-theft but will tell you it takes a 100 ohm resistor.

        Comment


        • #5
          Originally posted by lifesaver87 View Post
          Good Morning, Afternoon or Evening fellow Katriders

          So first things first, my name is Keith and as the title of this thread suggests I'm new to motorcycles and I have inherited a 98 600f. It's kind of a long story but a lady friend said if I could get the bike running i could keep it. Having no experience with motorcycles doesn't make me a total weenie, I have been a mechanic with Mercedes Benz for the last 10 years and I am no stranger to hack jobs and wanna be custom tuners.

          More about the bike, she bought the bike non running because she was convinced she could fix it, after sitting for a year plus god knows how long it's my problem now. The story goes she bought it from a friend of a friend who tried making it a race bike needless to say they fell short of that goal and got rid of it. The bike was laid down and the fairings are more or less junk but the frame made it out unscathed. The wiring is a nightmare with cut wires and loose connectors that lead nowhere. I will be uploading pictures tomorrow so you guys will be able to see more clearly.

          What I've done thus far, carb rebuild/ cleaning/ bench synch (thanks to video thread carb 102), new fuel lines+ filter, spark plugs only because the wires looked really good, oil+filter, air filter+cleaned box, hose clamps on all rubber hoses. Pretty basic tune up type of stuff.

          Now the problem is a no start, no power at the plugs and no power to the coils, on a Mercedes I can just pull up a wiring diagram and break out my meter no problem but so far I can't seem to find the right information. Also since the history of the bike is shady I'm wondering if somebody tried to hotwire it, in an ignition thread I read about a safety feature for anti theft. I have power, the lights come on, voltage at the battery is good 12.9. The starter cranked when I power it directly, and the starter relay gives an audible click when power is directly applied so I can comfortably narrow it down to ignition or cut off switch problem.

          Can any of my new friends point me in any direction or post a writing diagram, words of encouragement I'll take anything to be honest.
          +1 Avatar Picture...

          Comment


          • #6
            just a little update

            I thank you guys very much for your feedback, attached are some pictures of the wiring that I have been so lucky to come in contact with. I needed to order some new leads and a fuse for my multi-meter since I have taken it out of storage so testing will take a few more days.

            I have downloaded the manuals as suggested but it took me a while to find exactly what I was looking for. There is a wealth of information here on these pages so i'm sure i'll have this thing running in no time.

            With that being said, i removed the instrument cluster so i could get the connectors prepped for testing later this week. While the connectors were dangling there was a steady and consistent stream of water running out of the connector that runs to the cut off switch. Some what of a red flag. Whenever I get a car at Merc with water damage we just automatically order a new harnesses because we know that the insurance companies are always going to pay but does a wet harness automatically warrant a replacement?

            I will have updates later this week, Thanks again guys!
            Attached Files

            Comment


            • #7
              Originally posted by lifesaver87 View Post
              While the connectors were dangling there was a steady and consistent stream of water running out of the connector that runs to the cut off switch. Some what of a red flag. Whenever I get a car at Merc with water damage we just automatically order a new harnesses because we know that the insurance companies are always going to pay but does a wet harness automatically warrant a replacement?
              No. These bikes are left outside all the time, and the wiring gets wet. Riding in the rain for example will leave you with almost no spot dry... in or out.

              A good cleaning and inspection of all the connections would be a good idea. Sitting is much worse than just wet. Prior owners are worse than that.

              Krey
              93 750 Kat



              Modified Swingarm, 5.5 GSXR Rear with 180/55 and 520 Chain, 750 to 600 Tail conversion, more to come. Long Term Project build thread http://katriders.com/vb/showthread.php?t=96736

              "I've done this a thousand times before. What could possibly go wron.... Ooops!"

              Comment


              • #8
                Nurse pass the wrench! Welcome to kr and good luck getting everything back to running order.

                Comment


                • #9


                  Does this diagram apply to the 98 600?

                  As i'm reading through the how to threads I almost started crying (from laughter) thinking about when I did the petcock rebuild. So the previous owner had a leaky petcock and his or her fix was to put an epoxy around the square section of the petcock where the diaphragm sits. I didn't know I was going to be in a forum otherwise I would have taken pictures.
                  Last edited by lifesaver87; 05-14-2014, 08:23 AM. Reason: Automerged Doublepost

                  Comment


                  • #10
                    Yes that diagram should apply to the 98 600 as well.

                    Help Support Katriders.com via Motorcyclegear.com

                    Comment


                    • #11
                      Awesome, Thank you!

                      I had assumed as much because there wouldn't be much of a difference in the wiring but working in the dealership we have to be a nazi about those things. I'm going to run the electrical tests tonight if it's the wiring and not the sensors i'm going to order a new harness. I'll post an update by friday for you guys!

                      Cheers

                      Comment


                      • #12
                        If the harness is all jacked up to start with, I'd personally rather spend the $ for a new one in decent shape. I hate chasing electrical gremlins. Good luck, welcome to KR!
                        1998 Katana 750
                        1992 Katana 1100
                        2006 Ninja 250

                        2006 Katana 600 RIP - 130k miles

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                        • #13
                          I'm going to test out the last of the sensors today if they check out its on.

                          Comment


                          • #14
                            Just an update

                            My phone is not cooperating but I took some pictures of the harness over the weekend while I was running my electrical tests and purchased a new harness and engine cut off switch.

                            While testing the harness I found some pretty extensive "electrical work" had been performed by a previous owner and it would have been silly to attempt to repair all of it. So I picked up a harness that included the ignition switch to help me cover my own electrical ass. It should be here by the end of the week so hopefully by Monday i'll post a picture of a running motorcycle.

                            Thanks for the help guys.

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                            • #15
                              good luck. there is an ignition fuse.
                              never sleep with anyone crazier than yourself sigpic2011,2012,2013,2014,2015,2016

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