Bike stops when clutch let out

[notme]

It seems that if I move the junction box (while it is plugged in) this can cause it to cut out as soon as the clutch is let out. Then if I move it to a new position, it will move forward with no issue.

There's something dodgy inside that box then. What exactly is this box? If you are testing diodes inside it, is it the regulator/rectifier you're talking about? upload pix and or a pic/scan of the relevant item in the wiring diagram.

Also, to help pinpoint the problem you could put the bike on a stand or loosen/remove the chain or something similar so that you can put it in first and let the clutch out without the bike moving - then you can wiggle things away and watch for the bike to die.

[Mikewazowski]

Here is a wiring diagram showing the Junction Box in the top left corner. The Junction Box also houses the fuses for headlights and whatnot.



I've ridden the ZXR a number of times since I cable-tied the plug into the Junction Box and it hasn't misbehaved yet. Time will tell, but I hopeful that I may have found the culprit. I'm going to grab a spare Junction Box that I can swap in if this one gives me grief again.

Fingers crossed that I've nailed it this time!

[notme]

The diagram looks like it is part of a series of diagrams that show more detail...


Anyway - there is no clutch switch shown on the diagram - is there one on your clutch lever? If there is, and you can make the problem happen by moving the fusebox/junction box, then the wire that comes from the clutch switch is dodgy at the junction box end. Maybe the clutch switch is in series with the sidestand?

Regardless, if you can make the fault occur by wobbling the junction box, then there is a dodgy connection at the junction box. Find and fix it, and you'll have no more issues. Cable tying it is a temporary solution, and I wouldn't bother with a spare junction box unless you find that the fault is inside it - most likely all you have to do is clean up a plug or socket or wire going to the box.

Upload pix of any dodgy connections if you want help fixing them...