Need Help!!! (Kawi won't start w/new battery)

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sonny62

Well-known member
I replaced the battery on my 06" Kawasaki 636 and for some reason the "Fuel light remains on and the bike wont start? I checked the fuel line and it seems fine and is not pinched anywhere. The bike just tends to crank up but wont turn over and start..

Has this issue happen to anyone else? All and any suggestions will be greatly appreciated..

Sonny
 
Sane_Man

Sane_Man

Totally Tubular
Did you charge the battery after you bought it?

It needs to be charged for about 12 hours before using it.

Also, where did you buy it? If you bought it mail order, you have to pour the supplied acid into the battery before use. If you picked it up locally, the acid was put in at the store, but regardless, you still have to charge it before using it, using a trickle charger or battery tender.
 
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sonny62

Well-known member
Sane_Man said:
Did you charge the battery after you bought it?

It needs to be charged for about 12 hours before using it.

Also, where did you buy it? If you bought it mail order, you have to pour the supplied acid into the battery before use. If you picked it up locally, the acid was put in at the store, but regardless, you still have to charge it before using it, using a trickle charger or battery tender.
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I purchased the battery from a dealership and they charged it for more then 24hrs from what they told me. The lights are pretty bright and are working fine compared to before i replaced the battery. When i changed my battery on my 00" R6 it started up just fine and didnt give me any of these problems. not sure why the kawi is giving me this headache...??
 
Sane_Man

Sane_Man

Totally Tubular
Was it running ok, before you swapped out the battery?

If it was, I'm thinking you either left off a ground wire on the battery (seen that before), or shorted the battery to ground and popped a fuse, when you installed it.
 
Burning1

Burning1

I'm scareoused!
Fuel light...

Do you mean the low fuel indicator, or do you mean the 'Fuel Injection System Error' light?
 
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sonny62

Well-known member
It's actually the Low fuel indicator. The tank has enough gas. The speedomter also blinks and shows "FUEL".
 
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Burning1

Burning1

I'm scareoused!
If your bike is like mine, the fuel light is a simple circuit with a thermistor in your gas tank. The fuel light staying on might suggest that you're out of fuel, which would certainly prevent the bike from catching, but otherwise it's not diagnostically relevant.

Edit: I think you're using the term 'turn over' incorrectly. Turn over typically means that the starter is turning the engine, whether or not a cylinder actually fires. It's possible for the engine to turn over, without 'catching.'
 
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Flying Pig

Flying Pig

Still learning to ride
I had gas when I left it with a dealer.
Well the gas light went on half-way on the way over to the dealer.

I got a call saying that they were done and they even did an oil change for me since that was part of the issue.
I arrive there and try to start it and for the life of me could not get it to start.
As the service manager wheels their tank of gas over to where I'm struggling, I decided to stand the bike upright instead of it angled position on the kickstand, and voila, it starts right up, no complaints from the R6.

So, with that small story/digression aside, is the bike on its kickstand, or upright? when you are trying to start it?
 
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sonny62

Well-known member
Flying Pig said:
I had gas when I left it with a dealer.
Well the gas light went on half-way on the way over to the dealer.

I got a call saying that they were done and they even did an oil change for me since that was part of the issue.
I arrive there and try to start it and for the life of me could not get it to start.
As the service manager wheels their tank of gas over to where I'm struggling, I decided to stand the bike upright instead of it angled position on the kickstand, and voila, it starts right up, no complaints from the R6.

So, with that small story/digression aside, is the bike on its kickstand, or upright? when you are trying to start it?
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I tried both upright and on the kickstand but still no luck. I know theres two gallons in there because I used a gas container that carried two gallons.
 
Sane_Man

Sane_Man

Totally Tubular
Sonny M said:
I tried both upright and on the kickstand but still no luck. I know theres two gallons in there because I used a gas container that carried two gallons.
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So did you run out of gas, then poured two gallons in the tank to try and restart it, but are still getting a low fuel light? Did you then run down the battery trying to start it, so you installed a new battery?

The way you are describing your problem isn't really clear. In fact, it's very confusing trying to figure out exactly what's your problem.
 
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sonny62

Well-known member
the bike sat in my garage for about 7 to 9 months which resulted in to the battery drying up. I then charged the battery, got the bike to run and brought it to my cousins house who then rode the bike around, ran out of gas and parked it in his garage for 3 months. I bought a new fully charged battery this past weekedend and installed it yesterday.

After battery installation:
- The bike is cranking up but wont fully start
- The "Low Fuel" light is on
- The gauge is also blinking the word "FUEL"

I tried starting it on the stand, sitting straight and adding two gallons of fuel but still have no luck...
 
Sane_Man

Sane_Man

Totally Tubular
Sonny M said:
the bike sat in my garage for about 7 to 9 months which resulted in to the battery drying up. I then charged the battery, got the bike to run and brought it to my cousins house who then rode the bike around, ran out of gas and parked it in his garage for 3 months. I bought a new fully charged battery this past weekedend and installed it yesterday.

After battery installation:
- The bike is cranking up but wont fully start
- The "Low Fuel" light is on
- The gauge is also blinking the word "FUEL"

I tried starting it on the stand, sitting straight and adding two gallons of fuel but still have no luck...
Click to expand...

This sounds totally different then what you described initially.

You need to turn the key to the on position, and wait for the fuel injection sequence to cycle. Then turn it off for a few seconds, then back on again. You may have to do this 4-5 times to get fuel back into the injectors. Then try to start it.

If it still won't start, you may have sucked up crud from the bottom of the tank, and clogged up the fuel filter. To fix this, you will have to replace the filter. The worst case scenario is that you burned out the fuel pump by running it dry. You will have to disconnect the fuel line to see if it is pumping fuel to test the pump.
 
ST Guy

ST Guy

Well-known member
It's also possible, that between the two long periods of not running, that the fuel has gummed up on the inside of the system and you might be looking at some sort of fuel system overhaul. But try turning the ignition on for 10 seconds, turn it off, turn it back on, etc. for a few times. Then try starting. And while you're doing this, you might consider removing the headlight fuse to avoid any more drain on the battery than is necessary.

FYI: When I gas powered device is left to sit a long time, a fuel stabilizer like Stabil should always be used. And a Battery Tender will avoid the need for a new battery. Properly stored and put away, a bike can fire up instantly after long periods of non-use.
 
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