actual starter? All I get i? All I get is a clicking sound from the relay switch when I push the start button. I tried checking to see if it would crank by touching the post with a screwdriver and got nothing not even a spark. It will start by pushing off in second gear.Last year the starter hung while I was starting it.
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I have a 1980 kz440 Kawasaki. How can I tell if the starter relay is bad or the
- Thread starter stevbeav5
- Start date
A clicking or 'chattering' relay usually means the battery is weak, but if you are sure the battery is good, then you could try removing the starter and bench testing it. If the starter has worked ok since your hung starter problem last year then I wouldn't expect that that has caused any issues.
To check the relay, try disconnecting the positive (starter) wire from your starter motor. This will remove any load from the battery when attempting to crank. If the relay clicks once as you push the start button and does not 'chatter', then the relay is probably ok.
For the bench test use a healthy battery and connect the battery negative to the main casing of the starter motor and connect the battery positive to the positive terminal on the starter motor. Hold the starter in a vice if you have one, or put your foot on it. If it turns then your starter is probably ok. If not, then the starter has probably had it.
To check the relay, try disconnecting the positive (starter) wire from your starter motor. This will remove any load from the battery when attempting to crank. If the relay clicks once as you push the start button and does not 'chatter', then the relay is probably ok.
For the bench test use a healthy battery and connect the battery negative to the main casing of the starter motor and connect the battery positive to the positive terminal on the starter motor. Hold the starter in a vice if you have one, or put your foot on it. If it turns then your starter is probably ok. If not, then the starter has probably had it.
Captain Awesome
New member
If your relay is clicking, it is probably good. When you hit your start switch, 12V goes to the relay. The relay will then switch (click) and the current from your battery will go to the starter. You can test a relay with a multimeter. But I'd be willing to bet you need a new starter if your relay is clicking and your primary isn't moving at all. You can buy starter rebuild kits for a cheaper price.
ok.. you can take a 8 gauge jumper wire and run from the battery and touch the starter positive post . if it turns over it is the relay .. if not it is the starter . just note . the kawasaki KZ 400/ 440 starter are known for blowing the oil seal in the front of the starter and filling full of oil . That wears out the brushes ,armature commutator and shorts out armatures most of the time . I own and run a business that rebuild motorcycle starters, starters, and alternators for over 24 years . I have rebuilt hundreds of 440 starters .. most were full of oil . . we get 59.95 to rebuild the starter or $69.95 exchange just in case you need it rebuilt. I have in stock. all parts we rebuild have a year warranty on the starter . I also can sell you the seal or a rebuild kit . but if you just need to know more about the starter . Be glad to break down the 440 starter . I know every part of it .
bikinkawboy
New member
To test the relay, with the battery charged up, take either a very heavy piece or wire or metal pliers with uninsulated handles and using the handle end, touch both of the large lugs on each side of the relay. If the relay is bad, it will now make a big spark and cause the starter to crank over. If it doesn't, either the battery is shot or the starter is bad.
To rule out the starter, hook jumper cables up to a car battery, hook the positive clamp onto the lug on the starter where the heavy cable attaches (make sure it doesn't touch the rest of the starter) and then touch the negative clamp to the bike frame. If the starter is good, it'll crank over. If not, bad starter.
To rule out the starter, hook jumper cables up to a car battery, hook the positive clamp onto the lug on the starter where the heavy cable attaches (make sure it doesn't touch the rest of the starter) and then touch the negative clamp to the bike frame. If the starter is good, it'll crank over. If not, bad starter.
ok.. you can take a 8 gauge jumper wire and run from the battery and touch the starter positive post . if it turns over it is the relay .. if not it is the starter . just note . the kawasaki KZ 400/ 440 starter are known for blowing the oil seal in the front of the starter and filling full of oil . That wears out the brushes ,armature commutator and shorts out armatures most of the time . I own and run a business that rebuild motorcycle starters, starters, and alternators for over 24 years . I have rebuilt hundreds of 440 starters .. most were full of oil . . we get 59.95 to rebuild the starter or $69.95 exchange just in case you need it rebuilt. I have in stock. all parts we rebuild have a year warranty on the starter . I also can sell you the seal or a rebuild kit . but if you just need to know more about the starter . Be glad to break down the 440 starter . I know every part of it .