Hello,

My ZForce 800 has been flawless till now !
Went on a 1000 km run in a neighboring province, good times - no issues

Coming back to our trucks, we stopped on a beach for a break, had been running through heavy rain for about 1 hour - turned the bike off as normal.
Jumped back on the bike and turned the key to start the fuel pump - hit the brake and turned the key to start - nothing.....
Pumped the brake a bunch - turned the key - still nothing.

We were pretty remote still, but managed to call my dealer who told me to swap the starter relay and another one other than the Fan relay - did so, and after 2 attempts, it started and off we went. Worked normally.

I finally turned it off to get supper, and after a couple pumps on the brake, it started and ran normally.
After an 8 hour ferry ride and a 7 hour truck ride, I am home and decide to power wash the bike - nice and clean.

Let everything dry for awhile, time to put it in the basement where I keep it. Could not get it to start. - Tried all the same tricks other than the
swap relays, so I pushed into the basement. Have not tried it today as I am at work.

The Wiring diagram shows a Brake Switch and a " Switch, Rear Brake " and a " Switch Front Brake " - the Front switch is tied to the key and the starter.

Has anyone seen this issue ?

Where is the Switch Front Brake Located ?

Thanks ( sorry for the long explanation )

 

[2015 Z Force 800 53/Trail EPS]

Can't tell you where but it's clear to me that water is getting in somewhere it shouldn't. Just a matter of finding it. It also appears that over the course of some time that water does start to clear itself. One common problem on the older ones is the kill switches not being water tight. Rain and washing lets water get in to the switches and corrodes the contacts as well as the key switches. 

Hey thanks,

I did have the issue with the switches awhile back so I lightly spray the dash now.
Googling showed me there is a switch on the Brake Cylinder that activates either the brake lights or the start switch or both.
Checking it tonight.... new part has 4 pin connector, so hoping it covers both.

I'll let you know what I see

Hello 2themax,
I had a similar problem on my 2021. Intermitent no crank. I replaced the aux2 relay, the larger 6 pin relay. That seems to have done the trick. In my case the relay was difficult to get out of the socket. I had to buy a 90 deg relay plier to remove it. Hope this helps.

Thanks, that is helpful.

I tore stuff apart last night to check the Brake switch on the master cylinder, seems ok.
I went back to the Fuse Box and switched the Small AUX start relay with the Brake Relay, which is what I did the first time ( putting them back in their original spot ) and the darn thing started ...

I'm still chasing the " Switch, front Brake "  - anyone know where this one is ?