Please help katana is dead

[cowboyup3371]

Replace that top fuse then and see if it changes things. You can get new fuses from any auto parts house.

[mike_of_bbg]

Yes, change the fuse. Then check the condition of your charging system immediately. Stator papers off the garage link from the GSR home page, or I think BassCliff has an improved version on his site.

[Shaun23a11en]

ok heres an update. I bought new fuses and replaced them all. I clean all the connectors up as well. I turned the key and the headlight turned on! I was very excited. Also, the high/low beam works, horn and guage lights work. The green nuetral light was on as well as the red oil light. this bike has not been started in about 3 years. I bought it off my neighbor. I turn the motor over with a wrench and it turns and feels good. the throttle linkage snaps back when fully opened. Now, when i turn the key all the way to the right, then push down and turn it more to right, this is the run position correct? when the key is in this position, my guages and headlight all shut off. I flip the red switch to run, press the start button and nothing. no sound at all. So, now everything works beside the starter. i know it cant run right now i need some thing to get it to that point but i would like to get it turning over atleast if i can. also, does the clutch need to be pulled in to start? why would the lights shut off in that key position? thanks for your help everyone i really appreciate it. here are some pics for all to see- my first bike

[Shaun23a11en]

another pic

[Shaun23a11en]

lights working for first time in 3-4 years

[mike_of_bbg]

Run position should be straight up and down as in your pic with the neutral light lit. Off, but not locked, is about 20-30 degrees counter-clockwise from there. There are two "lock" positions - all the way to the left and to the right. The one on the left is "all off", whereas the one to the right (clockwise) leaves the tail light on.

[mike_of_bbg]

That's a darned shame that someone let that bike fall into that shape. Hope you have great success fixing her up. Remember to be PATIENT. There's going to be a lot of maintenance to catch up on in addition to all of the obvious stuff that needs to be fixed. Particularly for a first-timer, it's going to be a months-long project to have a bike that runs well.

BTW, you should add your location to your profile. Who knows, there might be some GSRers near you who would be willing to come lend a hand if you get stuck. Or just go for a nice little ride once you get her rolling.

[cowboyup3371]

What Mike said about the key and then yes you may have to pull the clutch in. However, most of us disable that little safety switch and never have any problems so it's possible the PO did as well.

[Shaun23a11en]

ok so the position the key is in the picture with the lights is would be the position to start the bike then right? the clutch cable is extremely loose also. once adjusted, pull the handle all the way in, flip the red switch down and press the start button right while the key is in this position?

[mike_of_bbg]

Correct. Wonder if the clutch cable has snapped? Make sure you keep it in neutral then. How loose are we talking here? Does the clutch lever return out when released?

[Shaun23a11en]

Yea it returns but I feel resistance only maybe 1 inch from the hand grip. Also I guess there is supposed to be a yellow and green wire to the starter relay from the starter switch on my handle bars? the wire is not there. I have a small black and white wire. the black one from the starter. A large red from battery then I believe one or two smaller red ones on that same terminal. where would the yellow and green wire go?

[mike_of_bbg]

Black wires with white tracers are normally used for ground wires. I'd follow that one and see where it goes. Mine is an LZ but I would expect it to be very similar electrically to the MZ. The ground for the solenoid is its mounting to the airbox. There should be 3 terminals on top: two large as you've noted with cables coming in from the battery and out to the starter - and yes, the terminal with the red wire coming in from the battery should, indeed have a smaller wire headed off to the fuse box. The only remaining, small terminal is where your starter button's connection should go. Check that terminal for +12V when you hit the starter button (and hold in the clutch or, as noted, bypass the clutch switch).

You can "jump" the solenoid from the incoming battery terminal to the smaller terminal (if the solenoid is arranged as described - if not it may have been replaced and you should investigate!). If that works then you need to trace that starter control circuit and find the problem.

The fact that your main fuse was blown is an indication that the bike was having charging system issues. You may be in store for a stator and R/R replacement.

[mike_of_bbg]

The 550s were a bit odd in the clutch dept. in that the clutch cable goes to an actuator under the front sprocket cover. Once the actuator moves far enough, it will engage a push rod which runs its way through the motor and disengages the pressure plate. There won't be much resistance until you hit that.

[Shaun23a11en]

Ok on my starter relay, I have the terminal on the bottom right if were lookimg at an overhead view for the starter wire. The top left is from battery and to fuse block. the bottom left and top right are just philips head screws with nothing on them. . Where would the yellow and green wire go?

[mike_of_bbg]

On mine the Y/G wire is actually held on with a clip on the lower-left terminal; the wire itself is soldered to a pad a few mm to the right of it. I'll try to get a crappy cell phone picture of it at lunch.