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I wish there were lids for those small storage boxes on the racks though! I just need one more

Thanks folks for all the wonderful info. Appreciate you two always chiming in. Next time I'll know what to do . Check out the parts bike I scored today !

Anti seize should work at temp. Graphite powder mixed with oil, or black grease, or copper based anti-seize are all pretty anti-seize and heat resistant. I mostly just use a black grease to lube those bolts. It's got Moly something..

That would be good to do that every so often, i have been putting ani seize on everything including those bolts, dont know if it actually works because of the heat but couldnt hurt.

Yep, it sat outside for years. It's been "down" for at least 5 years.

And has it fixed the back-firing ? Those nuts at the head join, some owners manuals say that as a matter of routine maintenance they should be loosened and re-tightened. It's only about once a year they say to do it. It's probably in recognition of the fact those nuts seize.

Sounds like me Gw.. Old age and lack of use.. Now where's that shovel...

Yup. A squirt of CRC or WD40 once every now and again will keep the new switch working.. if it's a genuine Kawa switch anyway. Non-genuine, perhaps not. Silicon though can give off fumes that corrode, and it's likely to keep the water that does inevitably seep in trapped in. Silicon is awful stuff !!

Good point, but i think you will be OK just keep it covered out of the weather, its taken 22 years to get this bad, and probably sat directly out in the weaather for many of those years.

Thats good, it may have just been sticking a little not moving freely.

Ok. Things like to be used.. They get rusty and unreliable sitting around.

I doubt silicon will keep the water out for long. I'd use vaseline or some soft seal, but you need to be careful where it goes if the starter is a press contact, rather than a sliding contact. Press contacts get dirty easy and even vaseline can stop them working. Sliding contacts cut through vaseline or soft seal so those contacts can be covered in the stuff.

I tried starting it a few more times and finely got it started and it now starts first time.

👍

I'll be using gasket seal or silicone when I put it on the handlebar.

That sounds like a good choice, hope it gets you going.

Solenoid is fine. Start, kill, and headlight switch is badly rough inside. Copper contacts are black, metal retainer plates are rusted. A new switch has already been ordered.

I ended up welding it

Nut splitter is a good idea i have one and never think to try it, generally we dont think to try these things until we have already broken the nut off, but as a rule i always try something on muffler bolts that have never been removed 99 percent of the time they break.

Yeah, what Gw says...

Yeah it could be the solenoid, and a good test to verify that, is to give it a hard tap with a screwdriver handle, while holding the start button down. There is a danger though that if the solenoid earth is bad, or the start button does have a bad contact, or the isolation relay has a bad contact, or, in some bikes, the kill switch has a bad contact, causing low current to the solenoid windings, then the hard tap might just be enough to get the solenoid to move and operate with the low volts to the windings.. The best check for bad contacts or connections is to look for voltage drop through that windings circuit. If the voltage drop checks all pan out ok, then try tapping the solenoid.

If you can split the nut it will come loose. There are tools called nut splitters. You'd have to get one that could fit onto that nut if the space is a bit confined.

Check the bendix to make sure it is working properly, you might pull the starter out and check it out to make sure all the parts are in place and and no slop in the engaging gear.

This is a great benefit, and a great site, Admin thanks for all your support and hard work keeping the site going.

Starter button is definately a strong possibility but i have also had soloenids stick, may work a couple of times as you describe and then stick, and you have to giggle the start button or lightly tap on the soloenoid to get it to unstick.