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Anonymous Posted on Mar 21, 2010

ER-5 2004 - starter problems - roll start works

I have an ER-5, built 2004. It's been fine for a good few years, but has recently developed a problem starting.

What tends to happen is that when I switch it on in the morning, it will turn the starter a few times, but then the starter stops turning, and there's a pretty loud and quick "CLICK CLICK CLICK CLICK" from the area of the starter/relay. If I keep trying to start, occasionally the starter might turn a couple times before clicking, but then the clicking starts again. After a minute of this, clicking is all I'll get, and I'll have to roll-start it.

Any advice on a possible cause greatly appreciated!

br,
Hlynur

  • Anonymous Mar 25, 2010

    Got this answer from Dave Anderson off a kawasaki forumn (www.kawasakimotorcycle.org). I'll post it here for the benefit of others along with my own answer...

    "Hiya Hlynur,

    Yeah I did fix it in the end (or rather, my local authorised Kawi garage figured it out!).

    It turned out that the regulator (think that's the thing) was broken, so that it wasn't probably regulating the amount of charge going to the battery while the engine was running. The end-result was that the battery was being slightly *over*-charged all the time, which apparently is lethal to the life of the battery. I.e. a new battery will work for a while, but the relentless overcharging will very quickly kill the battery, rendering it unable to hold charge. Hence my batteries always stopped working, and it also explained why taking a battery straight from an external charger to the bike would allow the bike to start - the battery would hold a charge just long enough to do that and start the bike, but in normal use, the ability of the battery to retain the charge was killed by the repeated overcharging. Regulator the culprit.

    So the symptoms of this problem are accelerated death of multiple batteries that start out healthy. Solution is, change the regulator. You'd want to check the regulator to ensure it is broken before replacing though, because it was about ?100 for the part alone in Ireland where I am, it's not a super-cheap part. It is, however, cheaper than putting a new battery in every few weeks, and much less effort than trying to roll start your bike every time :)

    Hope this helps point you in the right direction!

    cheers,

    Dave"

  • Anonymous Mar 25, 2010

    Here's a follow up and how I "fixed" the problem.

    I just started using my bike again after a long cold winter and the first few days I always ended up roll starting it, driving about 5 minutes (to work) and parking. The motor never got heated properly. Then after cruising for a bit one day, motor all nice and warm, I switched it off and immediatly turned it back on again and voila! It roared to a start. Did this a couple of times (to get the starter "used to" turning the motor over) and then left it to cool down till the next morning. Next morning came and everything still worked like a charm :)

    Seems to me that after standing untouched for the whole winter the starter couldn't turn over the cold motor. Me abusing the ignition over and over (producing the click click click) didn't do the mechanism much good either so it got "used to" not being able to turn the motor over.

    Starting on a warm motor seems to have given it it's memory back, so to speak, so now I've been starting without fail the last 6 times, even on a fairly cold motor. So, today I am a happy camper!
    Ta for the help everyone!
    cheers,
    Hlynur.

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  • Contributor 47 Answers
  • Posted on Mar 24, 2010
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Your battery needs replaced. the battery does not have enough cold cranking amps to turn over the cold motor. i recomend a yuasa battery which is the same as the factory one.

Testimonial: "Thank you Greg, good advice, however the problem "went away" by itself... see my own answer for details... ta, Hlynur."

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