1993 Vulcan 750 // Starter // Junction Box Click - Kawasaki Vulcan 750 Forum : Kawasaki VN750 Forums
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post #1 of 35 (permalink) Old 04-18-2016, 11:49 AM Thread Starter
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1993 Vulcan 750 // Starter // Junction Box Click

Hello All,

I am having issues with starting this bike. Ive done all the newbie checks with the kick stand/kill switch and still no dice. Here are the symptoms. I try to start the bike and all I hear is clicking from the side of the bike. Since the bike is pretty old I decided to just replace the battery but that didnt help. So I went ahead and started to tinker and to see where the clicking is coming from which in fact was the junction box. I disconnected everything, cleaned all the connectors and put everything back to its original place and still no luck. Ive read on this forums that it might be something along the lines of a starter relay or starter solenoid issue, are there any ways that I can bypass the wires and to test these individually? Any help will be great !

Thank You
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post #2 of 35 (permalink) Old 04-18-2016, 12:00 PM
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Originally Posted by spbruski View Post
Hello All,

I am having issues with starting this bike. Ive done all the newbie checks with the kick stand/kill switch and still no dice. Here are the symptoms. I try to start the bike and all I hear is clicking from the side of the bike. Since the bike is pretty old I decided to just replace the battery but that didnt help. So I went ahead and started to tinker and to see where the clicking is coming from which in fact was the junction box. I disconnected everything, cleaned all the connectors and put everything back to its original place and still no luck. Ive read on this forums that it might be something along the lines of a starter relay or starter solenoid issue, are there any ways that I can bypass the wires and to test these individually? Any help will be great !

Thank You
Your Starter Motor "Relay" is mounted rightside of bike, close to battery box. Your Battery + Positive Cable connects to it. - -

Jumping the two large Terminals should turn the Starter Motor ....
which only verify's starter motor functioning/not seized .....

'86 VN750 13,700 mi -Stock
-Purchased 2008 w/8800mi
Replaced ALL Cables . Kuryakyn LED Voltmeter
SilverStar Ultra 9003/HB2 H4 Headlamp, Jardine Fwd Controls,
Iridiums DPR7EIX-9 & Wires, Tuxedo Mod, Coil Mod, P/U Sensor Mod, Fork Seals,
Splines Lubed - 11/4/2012 - MF AGM Battery
Additional Flashing LED Brake Light on Trunk
Dampers went out @ 13+K !
After TOC MCCT's..... so amazingly quiet I discovered a rattling heat shield on my stock exhaust !
...have a vulcan good day!

Last edited by WilliamTech; 04-18-2016 at 12:38 PM.
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post #3 of 35 (permalink) Old 04-18-2016, 12:39 PM
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Without access to the trigger wire from the key, you'd want to do that with a very heavy gauge wire. Normally you'd jump between input power and the trigger wire.

1986 VN750 27k miles
1999 EN500 32k
1983 GL650i in pieces. Someday it will ride again.
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post #4 of 35 (permalink) Old 04-18-2016, 12:51 PM
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Originally Posted by calebj View Post
Without access to the trigger wire from the key, you'd want to do that with a very heavy gauge wire. Normally you'd jump between input power and the trigger wire.
- - -
...what ^ he ^ said....

'86 VN750 13,700 mi -Stock
-Purchased 2008 w/8800mi
Replaced ALL Cables . Kuryakyn LED Voltmeter
SilverStar Ultra 9003/HB2 H4 Headlamp, Jardine Fwd Controls,
Iridiums DPR7EIX-9 & Wires, Tuxedo Mod, Coil Mod, P/U Sensor Mod, Fork Seals,
Splines Lubed - 11/4/2012 - MF AGM Battery
Additional Flashing LED Brake Light on Trunk
Dampers went out @ 13+K !
After TOC MCCT's..... so amazingly quiet I discovered a rattling heat shield on my stock exhaust !
...have a vulcan good day!

Last edited by WilliamTech; 04-18-2016 at 02:09 PM.
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post #5 of 35 (permalink) Old 04-18-2016, 02:07 PM Thread Starter
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What would be the steps for before, during, and after? What results should I be expecting? And if the results are in favor of a healthy starter relay, what would be the fix for it? Rewiring perhaps?
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post #6 of 35 (permalink) Old 04-18-2016, 04:56 PM
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How are your grounds?

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post #7 of 35 (permalink) Old 04-18-2016, 05:24 PM
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Originally Posted by OleDirtyDoc View Post
How are your grounds?
....

'86 VN750 13,700 mi -Stock
-Purchased 2008 w/8800mi
Replaced ALL Cables . Kuryakyn LED Voltmeter
SilverStar Ultra 9003/HB2 H4 Headlamp, Jardine Fwd Controls,
Iridiums DPR7EIX-9 & Wires, Tuxedo Mod, Coil Mod, P/U Sensor Mod, Fork Seals,
Splines Lubed - 11/4/2012 - MF AGM Battery
Additional Flashing LED Brake Light on Trunk
Dampers went out @ 13+K !
After TOC MCCT's..... so amazingly quiet I discovered a rattling heat shield on my stock exhaust !
...have a vulcan good day!

Last edited by WilliamTech; 04-18-2016 at 06:09 PM.
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post #8 of 35 (permalink) Old 04-18-2016, 05:43 PM Thread Starter
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ive cleaned off any gunk that was on both ends, tightly fastened as well.
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post #9 of 35 (permalink) Old 05-12-2016, 10:38 AM Thread Starter
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What would be the steps for before, during, and after? What results should I be expecting? And if the results are in favor of a healthy starter relay, what would be the fix for it? Rewiring perhaps?

Can anyone shed some light on this? And if anyone else can add some more checks to see what might be the problem. I have all weekend and clear blue sky to work on my bike
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post #10 of 35 (permalink) Old 05-12-2016, 12:40 PM
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Quote:
Originally Posted by spbruski View Post
What would be the steps for before, during, and after? What results should I be expecting? And if the results are in favor of a healthy starter relay, what would be the fix for it? Rewiring perhaps?
Hi spbruski,

Jumping the terminals of the starter motor relay as recommended will help narrow down where the electrical failure is in the system. If the starter motor turns over when the terminals are jumped, that eliminates the starter motor as a failed component, and lets us know that the ground and battery leads of the relay are good.

If all that is good, then the problem must be at the junction box (which is clicking, meaning the voltage from the start button is making it to the starter circuit solenoid inside the junction box) and the starter relay (or the relay's ground).

SO, short across the starter relay terminals first. If those are good, check whether you get voltage out of the junction box on pin 13 (yellow/red wire on the smaller 10 pin connector). The connector must be attached to the JB, but you can stick a voltmeter probe in alongside the wire to touch the contact.

If you're getting voltage there, then your starter circuit solenoid (in the junction box) is ok. That leaves either a bad starter relay or a bad connection into or out of the starter relay's primary (smaller/triggering) terminals.

Once you track down where the problem is, we can discuss whether rewiring will help, or whether a piece needs to be replaced.

Generally speaking, the junction box solenoid can be bypassed, but the starter relay cannot.

(of course, the starter may be fine and the ignition system may be to blame, but we'll cross that bridge if we need to)
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