First thing to check is if you got a new battery that has the umph to turn it. Next is to make sure you are getting a good solid connection on your battery and on the other side of the cables too.

Then after that take a multi-meter and check your voltages at each connection starting at your battery, then on to the next until you get to your starter. If you notice a drop in power go back to the previous connection and double check. That should narrow you down to the problem if it is there.

 

Kawasaki starters give little to no trouble. The problems are usually elsewhere.

 

Yeah, I figured this one was still good when I put the new starter on it, and it still drags. This is a real puzzler, for me. Never had one just solenoid click with a new battery and drag slow with a weak old one.

 

Remove one sparkplug from each cylinder, put bike in gear. By pushing, can you turn motor over?

Post back.

 

Yes the motor will turn.

 

I'm having the same problem on my '94; starter relay clicks and that's it. Prior to this happening, it would take some trying to get the scoot started. Unfortunately I can't be of any help as I'm still troubleshooting and am a novice when it comes to electrical systems. But I will be following this thread so good luck!

 

You will need a meter and know how to use it.
No meter/knowledge? We can help you with that too.

Post back.

 

Ok, I put my meter on the battery and the battery reads 12.5volts when I bump the start button it drops to 5 volts. Reads the same on both sides of the solenoid when the starter button is pushed. I now notice that the positive side of the battery cable gets extremely hot just from bumping the starter button and checking with the meter.

 

Couple of things that can cause your battery voltage to fall like that:

1. Bad battery.
2. Starter is stalled.

I do not think that corroded wire is the issue.

Could you do the following:

1. Take a voltage reading across the battery.
2. Turn on key. Take another reading.
3. Leave key on for a full five minutes, then take another reading.

Post back with the three readings.

 

Well, not saying you should do it, but if it were me, I'd bypass the solenoid and jump directly to the starter. If the starter flies over at that point then I'd have to seriously be looking at the solenoid or the cables going to it. Cables may look fine but sometimes if you peel back the cover you'll find a lot of corrosion which can cause this problem.

 

X 2 on it likely being a wiring issue. If all of the contacts are clean then cut back some of the insulation over the positive cable where it was hot and check to see that there isn't a partial break in the wires. This can cause the wires to become very hot.

 

You probably replaced the solenoid and cable needlessly.
You are going to have to pull the right side engine cover off and check the starter clutch, torque limiter and associated gear train for a problem.
The starter is being put under heavy load and that is why battery voltage falls so much and cable gets hot.
If the engine turns over easily by pushing in gear, then the trouble seems to be in this area.

Post back with your findings.

 

If I can piggyback the op's readings, mine cam out to be:
12.9 across the battery
12.5 with the key on
11.9 after 5 minutes

Is that indicative of a bad battery?

 

I do not like to see a battery drop below 12v after 5 minutes.
Your battery is just marginal, or partially discharged.
Make sure it is charged and then try again.

This is a quick and dirty test and not meant to catch all types of battery failures, but can give you a general state of the union.

 

The previous readings were taken immediately after tanking the battery off the charger, which read that the battery was fully charged.

 

OK, then my original thoughts stand.

 

Keep us posted, I'd like to see what the final outcome of this is. After chasing an electrical gremlin in the wifes 97 1500 for 2 years, I finally got everything good to go. I just don't like the way hers turns over. I feel it should spin quicker than it does, so maybe hers is a mechanical problem also. I was leaning towards the solenoid but everything tests fine. Mind you her battery doesn't die any longer, I fixed that, it just spins slower than I think it should.

 

New starter relay did the trick.