Versys 650 2009 65,000km not starting - Kawasaki Versys Forum
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post #1 of 34 (permalink) Old 07-12-2016, 10:22 PM Thread Starter
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Versys 650 2009 65,000km not starting

I have tried many things to fix my versys which refuses to start. Well I have been able to start it once in 20 attempts maybe, but most of the time the battery lose its charge.

However, interestingly enough, once started, it runs pretty well. Go figure.

Here what it does
No Video


What I have attempted so far not in a particular order:
1-changed spark plugs,
2-changed oil and oil filter - cleaned air filter and air box,
3-checked valve clearances (twice),
4-checked spark plug coil resistances (ok - coils cracked),
5-checked crankshaft sensor signal (ok),
6-changed crankshaft sensor anyway (for a used one);
7-checked wiring (actually found a few exposed wires around the gas tank and under the seat, fixed);
8-changed ECU for a used one (I really thought it was the issue as it started right after,but problem reappeared)
9-changed one-way starter clutch for a newer one (it actually reduced the nasty noise)
10-Ran the diagnostic but did not find significant info.
11-Changed and charged the battery many times.

If you have a good idea what could be the issue please chime in!

(I have bought and old DR650 - which I like a lot - as I could not find the issue with the Versys, but honestly, the V is irreplaceable)

Cheers!
Marc

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post #2 of 34 (permalink) Old 07-12-2016, 10:42 PM
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Your starter is still screwed up... Is your valve TIMING as it should?
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post #3 of 34 (permalink) Old 07-12-2016, 11:00 PM
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timing might be off, did you remove the cams when you did the valves?

yes im a guy.
Silvie=latin for. Of the forest /woods. Fox= Vulpine (also my middle name)

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post #4 of 34 (permalink) Old 07-13-2016, 12:12 AM Thread Starter
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Originally Posted by invader View Post
Your starter is still screwed up... Is your valve TIMING as it should?
I would rather say it is screwed again - how do I check the timing? Can you point me to the right section in the service manual?

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post #5 of 34 (permalink) Old 07-13-2016, 12:19 AM Thread Starter
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timing might be off, did you remove the cams when you did the valves?
No - just usual gap check.

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post #6 of 34 (permalink) Old 07-13-2016, 02:21 AM
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That's right. Manual does not mention that camshafts are in desired position at every second crankshaft rotation... You can check for proper timing at assembly position:







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post #7 of 34 (permalink) Old 07-13-2016, 07:27 AM
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Burnedstar notes that it runs OK on the rare occasion it actually starts:

Quote:
Originally Posted by burnedstar View Post
I have been able to start it once in 20 attempts maybe, but most of the time the battery lose its charge.

However, interestingly enough, once started, it runs pretty well. Go figure.
If the timing were off enough to prevent it from starting, I would think it would never start, or at least run really badly?

Question: When you run it until the battery dies, do you smell unburned gas at the exhaust pipe? That would suggest fuel is flowing, but no spark - an electrical problem.

If no fuel smell, than a fuel delivery problem (which *could* be computer/electrical)

Good luck!

Rob in KC
'14 Versys 650
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post #8 of 34 (permalink) Old 07-13-2016, 07:35 AM
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Fuel Pressure or Ignition

The ran once could prove my suggestion as wrong, but do you have #1 plug wire on #1 plug?
Others have suggested fuel, how old is this gas?
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post #9 of 34 (permalink) Old 07-13-2016, 07:47 AM
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Have you checked your fuel system real good? Did not see a mention of that. What kind of fuel setup are you using in the video to try and start? Different ways of doing it on a fuel injected bike, just wondering. I agree with Invader on the starter, sounds horrible. Another question, with all the start attempts, have you thought about changing your start relay? Contacts gotta be in pretty bad shape by now. Anyway, Good Luck and report back.
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post #10 of 34 (permalink) Old 07-13-2016, 09:19 AM
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How old is that battery?
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post #11 of 34 (permalink) Old 07-13-2016, 09:54 AM
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Quote:
Originally Posted by burnedstar View Post
I would rather say it is screwed again - how do I check the timing? Can you point me to the right section in the service manual?
section 5 - page 24
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yes im a guy.
Silvie=latin for. Of the forest /woods. Fox= Vulpine (also my middle name)

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post #12 of 34 (permalink) Old 07-13-2016, 10:32 AM
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Its my vote for a fuel problem. Check the list of items the ECU doesn't give fault codes. It is a short list.

Since the bike appears apart, a quick check of the fuel pump is my recommendation. Just remove the pump, and put it in a small bucket of gas. Connect a piece of tubing to the output tube on the fuel pump and apply 12V to the red and black wires. If the flow is any less than a constant, strong stream of fuel, then you may have found the problem.

I just went through a pump failure. To make a long story short, I believe the pickup screen was clogged and that caused the motor to fail.

Hope you find the problem soon!
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post #13 of 34 (permalink) Old 07-13-2016, 01:09 PM Thread Starter
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Quote:
Originally Posted by Oldandslow View Post
Question: When you run it until the battery dies, do you smell unburned gas at the exhaust pipe? That would suggest fuel is flowing, but no spark - an electrical problem.

If no fuel smell, than a fuel delivery problem (which *could* be computer/electrical)
I have removed the spark plug coils with spark plug connected to its coil and grounded the SP housing then pushed start button. I tested both sides and no problem there - i could see the sparks. From memory (that was almost 2 months back now) I think there was a gas smell but not significant.

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post #14 of 34 (permalink) Old 07-13-2016, 01:12 PM Thread Starter
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Quote:
Originally Posted by onewizard View Post
The ran once could prove my suggestion as wrong, but do you have #1 plug wire on #1 plug?
Others have suggested fuel, how old is this gas?
Yes, I have checked that too and coils are on the the correct side. The gas was not older than a few days as I have been riding a few times and refueled a week before.

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post #15 of 34 (permalink) Old 07-13-2016, 01:17 PM Thread Starter
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Quote:
Originally Posted by BayouVersys View Post
Have you checked your fuel system real good? Did not see a mention of that. What kind of fuel setup are you using in the video to try and start? Different ways of doing it on a fuel injected bike, just wondering. I agree with Invader on the starter, sounds horrible. Another question, with all the start attempts, have you thought about changing your start relay? Contacts gotta be in pretty bad shape by now. Anyway, Good Luck and report back.
The fuel line (not visible) was still connected to the gas tank (also not visible).

The starter is a good pointer, i'll check that. I have changed the start relay a year ago as it was giving random starter kick while riding at low speed. That was a memorable experience.

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post #16 of 34 (permalink) Old 07-13-2016, 01:19 PM Thread Starter
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Originally Posted by unstable_rider View Post
How old is that battery?
I changed the original one about 2 years ago. I have recharged many times attempting with a fully changed battery and even also with the changer still plugged in to rule out the battery.

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post #17 of 34 (permalink) Old 07-13-2016, 01:31 PM Thread Starter
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Thx all for the good info! Here the next things I'll add to the list:

12-check timing (section 5 - page 24)
13-inspect/change starter ($$$)
14-Check the list of items the ECU doesn't give fault codes
15-check of the fuel pump

Cheers!
Marc

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post #18 of 34 (permalink) Old 07-13-2016, 08:53 PM
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That starter motor does not sound OK. If you can bump start it and it runs well stop wasting time elsewhere, it's either the starter, the clutch or something electrical (wiring, grounds, solenoid) preventing enough power to get to the starter.
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post #19 of 34 (permalink) Old 07-26-2016, 11:49 PM Thread Starter
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Quote:
Originally Posted by invader View Post
::::
Here the timing image on my V:

Timing in


Timing Ex


It seems the exhaust sproket is a little off as the alignment mark does not show but is just a little below.

How bad is it?
Attached Images
File Type: jpg timing1.jpg (28.3 KB, 92 views)
File Type: jpg timing in.jpg (36.1 KB, 424 views)
File Type: jpg timing ex.jpg (33.1 KB, 420 views)

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post #20 of 34 (permalink) Old 07-26-2016, 11:51 PM
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