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Discussion Starter · #1 ·
Hey guys, I've been having this problem for a week, My 04 z400 won't fire up, everytime I try to start it I will hear a "click" from the relay. I did check the battery and it's charged at 12.6V so the battery seems to be good.

After doing some research on the forums I found out that the problem would either be a bad starter or a relay. Before I order a relay or try to rebuild the starter (something I have never done before) I would really appreciate if somebody would help me find out which of these is bad.

Thanks for the help.
 

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You can short the 2 cables at the relay. If the starter turns, then it is your relay.
 

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the 2 big ones on the relay
 

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Right... The only other possiblity would be if something happened to your ground cable. If you have any jumper cables handy, hook one end to the NEG on the battery, and the other end to a good ground like an engine mount bolt or something.

If at that time your starter still wont work, its definately the starter.
 

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Discussion Starter · #7 ·
how hard is it to rebuild a starter? i've never done it before so on a scale of 5 how hard is it? :p

Should i just get another starter? the dealership is trying to hustle me for around 300$ !!!!! but that's how it is in Canada.

I know they go for way cheaper on ebay or used on here but still, the rebuild kit is 40$ almost the price of a starter on here but I'd like to learn on how to rebuild it instead first. Let me know how hard it is I will be probably doing it. If you can point to me on some info on how to do it, I have a service manual but I bet this site has a great how to somewhere, and yes i did search, starter is a term a little bit too common. Thanks guys :)
 

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Discussion Starter · #8 ·
Alright so here's a little update about my problem. turns out it was a bad starter. I personally think it's really worth getting a starter rebuilt, it cost me 34$ and the tihng has new brushes in it. The brush kit at the dealership was 40$ and I never did the job, it would have been good for experience but since I have very little mechanic experience I prefer have the pros doo it for me.

So here's where I am now, the thing ran great and started great. The quad stalled on me and i tried to fire it up, no response, I was pretty pissed but I was lucky since I thought in the first place I had a bad relay I ordered one from a member on the forums. Turns out I change the thing and still nothing happens!!!! My second guess is the switch, I remember it had some corrosion inside and I had to get it cleaned once because it did not work. So i change the whole switch/wiring and still nothing... I was suposed to go ride today but I really don,t feel like having to take off my seat every time we stop to fire it up from the relay. what should I be looking for here? anyone has any ideas?
 

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Old bump, where can I find a starter rebuild kit?

Just pulled mine and I get nothing when I hook it up to 12.7V.
I've never seen one. I bought a cheap aftermarket starter off ebay and it's working great. You can always send yours out to a rebuild shop and they can test/rebuild it.
 

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Yea, was going to take it to autozone and have them test it for sure but I didn't make it over there yet. Ebay would be my first choice if I couldn't rebuild, but that $40 may have the same issue mine has now.

I didn't check voltage to the starter when it was installed, but I hooked up my battery booster with the starter off:

12A nothing
60A it spun, slow

I tore it apart, black carbon(?) dumped out, like gun powder everywhere. I haven't measured the brush limit yet but I can visually tell its below spec. The armature needs the insulators grooved down, its smooth and even.
 

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Listen it is definately your starter. I have tried to take apart 2 now and powder coat them and every time I put them back together I must screw something up because the bike starts once and then the next time around Click, Click just like yours. It's gonna be cheaper to just pick up a second hand starter. I priced out having them rebuilt and with the parts, labor, and down time my Dads friend Scott from Pirate Mx can set you up with one cheaper and he doesn't sell anything on his site that isn't in excellent condition but he doesn't always have everything he has listed on his site so look him up, give him a call and tell him Jim Humphreys referred you.Pirate MX XC About Us
Good luck
 

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Also bought one, less head ache all you need is to install it and problem solved. Rebuilding a stater is also not that accurate sometimes, if unlucky it will only last for a month or so.
 

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I purchased one local to me for one pound off eBay it was for a Honda streetbike
To get me by till I rebuilt mine but its still going strong so needless to say original still not rebuilt lol
 

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You can short the 2 cables at the relay. If the starter turns, then it is your relay.
What is you relay , I’m having the same problem but my earth wires are lying loose and I tried fixing that but still nothing the bike doesn’t make a sound when I try to start it
 
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