New Ignition, No Start, Short?

[JeremiahC]

So I had posted a part of this in another thread but I feel like that question is no longer relevant with this update.

I installed a new ignition switch in my 97 Kat 600 and found the 10amp ignition fuse to have been blown. I replaced it, and tried my luck. It immediately blew again when I pulled in the clutch to try and start it. I put in a 15amp fuse just to see if it would blow that, and as I tried to start it, it turned over twice and then blew that fuse. I previously thought that the new ignition was the problem, now I'm thinking there is a short in the wires somewhere. I rewired in a new male and female plug (where the ignition connects up under the handlebars) thinking maybe the connectors had shorted, but no luck. I'm guessing I'm going to have to do some major wire tracing to see where the problem is. Wondering if anyone has any helpful advice? Maybe like where those 4 ominous wires end up?


Another thing, when the fuse would short out, I also thought I could hear some kind of spark down around under the airbox.

[GSXFJim]

Check the 2 pin connector from the alternator that plugs into the harness, it's an orange and a red wire. I had a similar issue, the connector melted and the two metal pins touched, it would fire and short right away.
If the connector is melted you can get one from here, http://katriders.com/vb/showthread.php?t=133560

[JeremiahC]

Check the 2 pin connector from the alternator that plugs into the harness, it's an orange and a red wire. I had a similar issue, the connector melted and the two metal pins touched, it would fire and short right away.
If the connector is melted you can get one from here, http://katriders.com/vb/showthread.php?t=133560

Hey man, thanks for the response. Just got done checking to see if it was that connector and, as far as I can tell, it looks fine. Unplugged it and still have the short, which I know means the male connector could be at fault but I really don't see anything abnormal in it. In my experience with burned connectors, it usually looks melted somewhere haha.

Any other ideas on vulnerable spots? I'm pretty worried I'm gonna have to start tearing through wiring harness'.

[92xjunker]

Check the starter relay. You may have shorted the coil.

[JeremiahC]

Check the starter relay. You may have shorted the coil.

I think you might be right but I'm not sure how to go about confirming this? Or what all collateral damage there might be? I appreciate the help!

[GSXFJim]

Jump across the posts with a heave gauge wire, if you can get the bike to start and run with no fuses blowing, its the relay coil.

Something I just noticed, you replaced the ignition switch, did you get the correct year? I believe there is a difference between Pre and Post Kats.

[JeremiahC]

Jump across the posts with a heave gauge wire, if you can get the bike to start and run with no fuses blowing, its the relay coil.

Something I just noticed, you replaced the ignition switch, did you get the correct year? I believe there is a difference between Pre and Post Kats.

Definitely made sure to get the right years ignition because I didn't want to chance anything if the post didn't fit.

Just jumped the posts and about jumped out of my pants when it started turning over no problem. But it was without a fuse in it and with the key was in the off position.

If I put a fuse in it and turn it to the on position I hear like a weird whirring or spinning sound now and then the click of the fuse blowing right away, so I can't even try to jump the coil with a fuse in. Unless I jumped the wires and let it turn over and over and then turned it to on and THEN put a fuse in. Not really sure what that means. But it does turn over when I jump the posts, fuse or not, key on or off.

[GSXFJim]

... I hear like a weird whirring or spinning sound now..

You may have a CA model, that noise may be the fan... disconnect it. its on the left side.

[92xjunker]

could be.. if it is a CalI model. use a rubber hose or simular, use as a stethoscope to locate the noise if it's not.

[JeremiahC]

You may have a CA model, that noise may be the fan... disconnect it. its on the left side.

could be.. if it is a CalI model. use a rubber hose or simular, use as a stethoscope to locate the noise if it's not.

Not sure if it is a CA model, but I couldn't seem to find a fan. I did locate the noise, by feeling around for the vibration.

Here's a link to show you what it sounded like. This is what happens when I put in a 15amp fuse with the key in the on position. You can hear the buzzing as I put in the fuse and take it out:
[nomedia="http://www.youtube.com/watch?v=8S9-RlH-5zk"]Kat 600 - YouTube[/nomedia]


The thing in the pictures attached is where the noise is coming from. I can see that it's some kind of relay but I'm not sure to what.

[Kreylyn]

Pretty sure that is the side stand relay. That would cause a start issue if it was bad.


What are the wire colors going into it? I can partially see, but can you confirm?


Krey

[JeremiahC]

Pretty sure that is the side stand relay. That would cause a start issue if it was bad.


What are the wire colors going into it? I can partially see, but can you confirm?


Krey

Orange and green, orange and black, two orange and yellows, and green.

[GSXFJim]

[Kreylyn]

Orange and green, orange and black, two orange and yellows, and green.

Yep, side stand relay.

Krey