Hey guys, I have been wondering if this is normal and one of my mates said it isn't, Basically my start button is always powered as in no ignition on and you can still wind the bike over.
Yeah the key and the stop button do what they are meant to but you can wind the bike over at anytime (it does not start tho).
Your main relay is either seized in the 'RUN' position, or it's been bypassed (probably because it's seized in the 'OFF' position). http://fzronline.com/wiki/lib/exe/fetch.php?cache=cache&media=fzr600wiringdiagram.gif is the wiring diagram for a 600; they're very similar, and this is a heckuva lot easier to read than the horrid FZR250 diagrams floating about. This is potentially an unsafe situation; you may be able to start and run 1) in gear, 2) clutch out, 3) with the sidestand down. Basically, all your safetys are bypassed. I'd get it fixed.
Well, that much is good. There's a Blue/White wire comes from the start button to the master relay assembly, and another Blue/White wire from the relay to the starter solenoid. If those wires are jumpered/shorted/misconnected, this would cause the situation you're describing. Alternately, the 'Starter motor' part of the master relay is just plain jammed in the "Go!" position.
Here is a pic from this old post <!-- l --><a class="postlink-local" href="http://fzr250.com/viewtopic.php?f=20&t=3205">viewtopic.php?f=20&t=3205</a><!-- l --> As Don says about the relay, I would have to say that the safety relay is faulty or bypassed. The fzr600 and 400 diagrams are significantly different to the 250.. Just be carefull if using those.
Took the rear fairing off earlier to have a look at my starting circuit as I actually noticed this morning that if you put the bike in gear and hit the start button it will wind over with the clutch out and roll forward, One of the terminals for the starter on the main relay has broken off so they bypassed it so it is direct from the button, I will wire it all back up the next time I pull the front fairings off (I know I should do it ASAP), Here are some pics:
So I'm having this same issue, The ignition switched was wired straight to the starter coil, bypassing the relay. So I connected it all as it should be and the starter wouldn't turn over. Figured that the relay was seized or in someway broken so I bought a new (used) one off ebay. It arrived today its a little smaller than the one I have but It clicks louder when the relay is in use which is always a nice sound as you know its working. But still this one is doing the exact same thing as the old one. What are the chances of it also being broken in the exact same way? my clutch safety works, so does my side stand. Are there any other safety's that I'm neglecting to think about?
If it is not starting when the new relay is used, then look at the relay contact connections that you are using. If there are only two connections then this won't apply. As you say, the relay is clicking when you operate the sidestand or neutral switch and if it does not operate in on or off mode then the relay contacts are fault or you are not connected to the correct terminals. If all else fails then get a NEW horn or driving light relay and wire that in it's place.
