In for a pound

[kawonda750]

On to my next problem..

The starter worked in the fall before the engine came out. I had to replace the start button first but after that it did turn the engine. After re-assembly, all I got was the clicking of the solenoid so I replaced the solenoid with a new aftermarket one. All I get with the new solenoid is the same clicking. Battery is fully charged and reading 12.91 Volts.
Any suggestions?

[badgereng]

Try a different battery first….

Connect battery direct to started to isolate the button / wiring.

If that doesn’t work, pull the starter motor out and try spinning it over whilst not engaged to the engine.

[kawonda750]

Great. Thank you ...again

[karl pa]

Do you have a good ground wire and connection from frame to engine? The engine is mounted with rubber mounts.

[kawonda750]

I have the braided ground wire at the left back from the 10 mm top case bolt there to the frame. All other electrics work, lights signals, horn so I assume the ground is good. I will check it again and make sure the connection is clean and tight to be sure.

[karl pa]

All lights and horn use the ground of the frame so they will work anyway. If the ground is good, use a volt meter on the starter side of solenoid, if it shows 12 volts you have an issue with starter or cable. Check battery voltage while pressing start button, if it drops low you could have a weak battery or a mechanical bind.

[kawonda750]

Turns out it was the cable connection at the starter. Working well now. I would be tempted to switch to pod filters if I had to struggle with this airbox a number of times. It doesn't help that the rubbers are cold in my garage and stiff. I use my wife's hair dryer to soften them up and make them a little more flexible.

Thank you for all the input. I've had enough for today. Back together tomorrow.

[badgereng]

Troubleshooting gets easier if you keep it as simple as possible.

Break the problem down into its component parts / systems / subsystems and you won’t go far wrong.

If it was working fine before, you don’t need to stray too far.

Too many people tend to go way off tangent and introduce more fog than was initially present.

Glad you found it quickly.

[karl pa]

The problem with (it was working before) the engine was removed and rebuilt and reinstalled, that opens the problem to more possibilities

[kawonda750]

Another small roadblock on the way to the return to the road. It seems that I am missing the spacer that goes on the sprocket side of the rear wheel. I couldn't mount the chainguard after replacing the aftermarket rear shocks with stock ones. There was no room at the wheel. Checked the parts listing and saw what was missing.

I guess the enclosed chain guard that I removed had that built in. So , again, it is hurry up and wait for the specer to arrive from England. Hoping this is the last surprise. I am still waiting for the tank and covers from the painter too.

[kawonda750]

Finally getting there. The painter had the tank scanned and a close match for the original grey metallic is Suzuki 511 ZDL. Hopefully it will be finished by late next week.

[kawonda750]

Silly of me to think all would go well. I added coolant and checked to make sure no hose connections were weeping. All was well...until next morning when there was coolant running down the floor in a tiny river. There is a leak at the base of the cylinders. I made sure on assembly that the o rings were in place and they were. I now hear from a couple different people that the Cruzinimage rubber parts tend toward crappy. I have ordered genuine Suzuki orings and base gasket and will take the top end apart again and use the genuine parts.
Could this be a devil bike ? This is the 4th Gt750 I have done and the first with this problem.

[kawonda750]

So I think I know what I did wrong. The parts list on Partzilla says 3 of the o-rings below the base gasket. I put in 4. I put one at the blind hple in front of the centre cylinder. There are 2 by the left and 1 at the right. Can I assume that there is not one that goes at the blind hole by the centre cylinder and this is what caused the leak ? The blind hole has a ridge like the other 3 so I put in an o-ring.

I know, rookie mistake.....

I have been watching a video and the guy in it is using 4 o-rings. ???

[kawonda750]

I replaced the CruzinImage o-rings with genuine Suzuki. It was a major undertaking getting the cylinders back on while the engine was in the frame.

No leaks now. Best advice is to avoid the Cruzin Image o-rings or pay the price like I had to.