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kawasaki fx730v starter problems

Discussion in 'Mechanic and Repair' started by AC7BF, Oct 2, 2013.

  1. AC7BF

    AC7BF LawnSite Member
    Messages: 2

    I have 2 customers that i know of that there units starter solenoid clicks but engages the ring gear intermittently when one keeps turning start switch to crank the engine to start and run. even with new starter and new ignition switch battery is new and connections are good. my thoughts are that the starter drive is not messing the flywheel ring gear properly as both gears look good. as i feel the started drive gear is not engaging but is being stopped by the gears not going into gear until its bumped just few times or turned till it messes and then it cranks the engine an starts. this is a intermittent issue the solenoid clicks but starter does not run until the drive engages . I have searched this issue all over and have not found any results i know i cant be the only one with this issue . i have thought of machining the starter drive gear bevel a bit to see if this solves the issue. As i thought more research maybe done and see if there is a fix for this issue thanks everyone for any help or ideas as I still wait for Kawasaki tech support to respond to my requests as calling on the phone during work hours has resulted in long waits on hold and work must come first. That's why I am here on my own time at home researching this issue to solve for the customer and learn how to fix this issue ..
     
  2. Restrorob

    Restrorob LawnSite Fanatic
    Messages: 11,029

    Your issue isn't with Kawi or any of the parts you replaced, But with the equipment manufacturer......

    The problem is too much voltage drop in the wire from the ignition switch to the solenoid, Add a relay close to the starter on the machine frame. Run the ignition switch wire to the relay, Then run a 14ga wire from the relay to the solenoid, Power the relay off the battery cable post on the solenoid with 14ga wire. You should be golden after this install.

    Deere and another OEM had the same issues and put together a relay kit......
     
  3. Sharpcut 1

    Sharpcut 1 LawnSite Senior Member
    Messages: 450

    Yup, exactly what Rob said. Make a relay that will pull 12volts directly from the battery to the small terminal on your starter, activated by the key switch. You need a typical relay and 4 wire pigtail to do this. To test our theory, run a 10ga wire with an aligator clip right to your starter (unplug the factory wire) and touch the other end to the positive battery terminal. Be careful when you do this as it will spark and the engine WILL turn over. I bet you it never skips a beat. If it does, you have a ground issue where your engine isn't getting a ground through starter.

    P.s Rob, did'nt read your entire post before I posted. Sorry for a duplicate answer!!!
     
  4. Restrorob

    Restrorob LawnSite Fanatic
    Messages: 11,029


    Ummm...... I'll letcha slide this time...... ;)


    But...... No need for a relay pigtail, Insulated spade connectors work just fine and are cheaper too......
     
  5. AC7BF

    AC7BF LawnSite Member
    Messages: 2

    I like to give you guys a big thanks as the start relay on this mower had a burnished points inside the relay but a new relay did not correct the problem as I took the advice added a relay to the system used 10gage wire overkill but its on a commercial unit so what the heck. I wired it direct to the battery with a 20 amp fuse for the power connection a then 10 gage to the starter an used existing starter wire to engage the relay leaving all the safety switches to do there job. the starter cranked every time no more clicking yeah. thanks again AC7BF Frankie
     
  6. Restrorob

    Restrorob LawnSite Fanatic
    Messages: 11,029

    Good Deal !!! :clapping:
     
  7. hvern01

    hvern01 LawnSite Member
    Messages: 6

    Your issue isn't with Kawi or any of the parts you replaced, But with the equipment manufacturer......

    The problem is too much voltage drop in the wire from the ignition switch to the solenoid, Add a relay close to the starter on the machine frame. Run the ignition switch wire to the relay, Then run a 14ga wire from the relay to the solenoid, Power the relay off the battery cable post on the solenoid with 14ga wire. You should be golden after this install.

    Deere and another OEM had the same issues and put together a relay kit......

    Restrorob, Can you explain your solution in more detail, maybe a sketch? I'm having the same problem but am not sure how to add the other relay and how to connect switch and solenoid etc...
     
  8. hvern01

    hvern01 LawnSite Member
    Messages: 6

    AHA - Just figuring this system out, can you give me a more detailed explanation how to do this wiring, I am a bit confused what goes where.
    Sure would appreciate your help here. I'm having the same problem:wall
     
  9. Bill Kapaun

    Bill Kapaun LawnSite Senior Member
    Messages: 944

    Rob hasn't been active for awhile......
    Google Bosch Relay to get an idea of how it works.

    Pins 85 & 86.
    The wire from the KEY SWITCH that goes to the small tab on the solenoid will go to one terminal and the other terminal goes to ground.

    Pins 87 & 30.
    One will be 12V from the battery and the other will go to the small tab on the solenoid.

    You might also want to check the engine mounting bolts. If loose, the engine could be shifting around enough to cause grounding issues.
     
  10. BigFish

    BigFish LawnSite Gold Member
    Messages: 3,782

    RELAY.JPG
    Ya wanna use 14ga. wire for the B+ #30 and the #87 from relay to start solenoid.
    Normally ya can pick up the B+ goin' to #30 at the solenoid/battery cable terminal.
     
    Last edited: Jan 10, 2017

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