Hi Everyone,
Ive read through the threads in this section but havent found anything that helps solve my problem.
First, let me start off by saying my unit has less than 500km. The issue begin like this, probably around 300km.

When starting the unit, turning the key to the "ON" Position, dash lights come on, everything checks out. When fully turning the key in to start the machine, sometimes it would start, sometimes not. It was like I had to very slowly turn the key just past the on position to hit the sweet spot and it would start up. I got by like this for a few months as I only used the machine every so often.

On the last ride, which was last year, driving down the road and the machine was cutting in and out, like trying to stall by loosing all power. Well it did and never started up again since.

I thought it was a dead battery but no, battery was replaced new and still wont start.

I thought perhaps the starter solenoid was to blame and so it was replaced but still same problem.

Where do I stand now? I can turn the key to the "ON" Position but when going all the way to start, the dash turns off while the key is being held in the start position. When it returns to the on position, the dash comes back on.
Im lucky that my father has the exact same unit (that works!) and so I tried the following to no luck.

-Replaced the ignition switch
-Replaced the ECU
-Replaced the fuel Pump
-Swapped out fuses and relays.

I can jump the starter solenoid and turn the starter over. Normally, when the key is turned to the on position, you hear the fuel pump prime, but mine does not. I am at a total loss. Ive nearly replaced the major/easy components with my fathers machine but still the same issue. Its got to be a short or bad wire connection.

Having said that, I did find some pretty bad corroded connections at the ECU on the 12 pin male/female connector. I ended up cutting the connectors off and joining the wires directly thinking this was the issue, but still no change.

Im hoping for help to start looking at the right places. I did get the wiring diagram and service manual which helps but im no electrical guru.

I know this is a lot but I am trying to be thorough to explain what Ive done.

Please ask any questions and I sincerely appreciate any help or advice from the members here.

Thank You.

[2015 Z Force 800 53/Trail EPS]

There was a lot of main fuse connector/holder problems. They had some internal crimps that broke connection or partly broke connection. This does not blow the fuse but can cause the symptoms you are talking about. Inspect it very close and test it..turn the key on, then the lights on high, then flex the connector around and see if the lights change at all. If so, cut it out and slap a new one in.

While you are at it check the grounds and the battery terminals.

Ok Thanks Ill check tonight!

Did you ever get this worked out? I am very similar issues with my 500 HO on my 2021 ZForce, I cannot trace it.