[Wulfonce]

Hi folks,

I just bought a 2022 Z-force 800 Trail model.  I've put 120km (pavement) and 5km (off road).  I went to wash it the other day and it wouldn't start.  I turn the key and here the fuel pump noise,  the dash lights up as normal, everything works fine,  then I go to start... *click*.  I try again...  *click*.    I hear the sound of the starter solenoid engaging but the engine doesn't turn over.  I check the battery with a high end charger.  Its showing 12.8v and 100% charge.  I check the terminals,  they are tight.  I check the main fuse under the seat,  that's connected.  I check the engine grounding wire, its attached.  I check all the fuses with a volt meter, they are intact. I checked the starter pins with a tester,  no faulty ground.  I even disconnected the battery and let it sit for a few hours to see if something would reset itself...  nope.

Then I notice a blinking light on the dash.  Its giving me code 0563 which in the 2017 models means high voltage warning.  I looked in the manual and see no reference or explanation for any codes.  I tried googling it, and I'm unable to find code info relating to the 2022 models.  I emailed the dealer for advice.  They are located 2.5 hours away and I would really rather not trailer it back to them if its something I can fix myself.

I don't really know what my next steps are.  I feel like I've checked everything I possibly can.

Any advice would be greatly appreciated.

 

[NMKawierider]

High Voltage codes usually happen when either water had gotten in something it shouldn't such as the rectifier/regulator connector or the kill switch...or while running the regulator has failed. Sense it isn't running it's not over generating so must be water somewhere it shouldn't be. None of the switches on the dash or the ignition switch are water proof so avoid them with much water pressure. You can take the rocker switches apart but I assure you, Chinese-made rockers don't like coming apart or going back together. Better to use some kind of drying agent like spray contact cleaner. Check other connections that may have gotten wet but it will be an EFI-related system connector that has leaked..
Codes:

[Wulfonce]

Thanks for the tip.  I'll give it a try, however this happened before I washed it so I'm not sure how it could have gotten wet.   We're currently in a drought here in southern Ontario,  I'm not sure how anything could have gotten wet.

[NMKawierider]

Then with the key on and in the starter position check the voltage both in and out of the main fuse. Many have had issues with the fuse holder's internal crimp connections. One would think it would give a low power error but...it is Chinese so...

[Wulfonce]

Thanks budd.  I'll give that a try on the weekend.

[doug80638]

Also jump the starter solenoid to make sure the starter will turn over. If it does, replace the solenoid. If it doesn't, suspect the starter has failed.

[Wulfonce]

Also jump the starter solenoid to make sure the starter will turn over. If it does, replace the solenoid. If it doesn't, suspect the starter has failed.

Nailed it.  That's what the problem was.

I checked the solenoid with a volt meter,  its working fine.  I have 12.8v arriving at the starter motor pin,  it wont turn.  Even tried a direct jump from the battery,  still wont turn.  I called my dealer and they want me to trailer it back to the shop to be fixed,  if I don't I'll be paying for the $380 part myself.  That's an easy decision though.  2 hours each way, pick up and drop off,  8h of my time plus gas.  I'll just buy a new one.  A quick google search suggests they are way cheaper then $380. 

Can anyone suggest a good quality starter to buy?  Not the cheapest, I would like good quality.

[NMKawierider]

Glad you found it. I don't know of anyone that makes an aftermarket starter for a CFM. Probably have to get one of there's but pull yours first and tear it down. Might be able to clean it up, resurface the commutator and brushes, lube the bearings and off you go. Never know.

[doug80638]

Starters are pretty simple devices. I have had great luck over the years disassembling , cleaning, and lubing to restore functionality. This all assumes that the windings ohm out good, and brush contact is OK.