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TOPIC: fuse keeps blowing everytime I kickstart - HELPpls

fuse keeps blowing everytime I kickstart - HELPpls 2 years 7 months ago #516921

  • eugrub
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Hello all,

I bought 1982 Kawasaki KZ750 M1 CSR Twins 3 weeks ago. It was running good until I removed wiring because last owner cut some wires and removed them. I wanted to make it look clean but somehow I screwed it up. I couldnt get it running at all. I decided to buy everything wiring harness from Ebay that came off same bike same year. I put it back together but some harness are not there since last owner removed it. I tried my best to follow harness and wiring diagram. When I turn key on, the headlight will come on but very weak. It was bad battery. I bought new one and put it on. Light comes on really bright then I try to kickstart and fuse blew. I replaced the fuse and tried to kickstart again but fuse blew again. Something is wrong. Fuse in small black box it says Main. Im not sure what main is. Please help me. I really want to get this running again and ride it.

Can I remove the engine kill switch? What wires do I need to cut?
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fuse keeps blowing everytime I kickstart - HELPpls 2 years 7 months ago #516930

  • Kawickrice
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You have a dead short some where, the main is your main fuse circuit. You need a wiring diagram and start tracing wires in question (main circuit) You will open a big can of worms if you start hacking wires (kill switch for example is a safety device). You need a test light and meter to diagnose.

Look for a pinched wire that the kicker might be rubbing on when it is being kicked or and loose grounds frayed wires etc.
73 Kawasaki Z1
82 Suzuki GS 1100
74 Yamaha RD 350 (My two stroke toy)
77 Kawasaki KZ 650B-1 (My putt around bike)
80 Indian Moped (My American Iron)
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75 Suzuki GT550
74 GT 380
79 RD 400 Daytona Special
72 Honda CL 175
74 Honda QA 50
73 Honda Trail 90
Tampa FL
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fuse keeps blowing everytime I kickstart - HELPpls 2 years 7 months ago #517015

  • Patton
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eugrub wrote:
Hello all,

I bought 1982 Kawasaki KZ750 M1 CSR Twins 3 weeks ago. It was running good until I removed wiring because last owner cut some wires and removed them. I wanted to make it look clean but somehow I screwed it up. I couldnt get it running at all. I decided to buy everything wiring harness from Ebay that came off same bike same year. I put it back together but some harness are not there since last owner removed it. I tried my best to follow harness and wiring diagram. When I turn key on, the headlight will come on but very weak. It was bad battery. I bought new one and put it on. Light comes on really bright then I try to kickstart and fuse blew. I replaced the fuse and tried to kickstart again but fuse blew again. Something is wrong. Fuse in small black box it says Main. Im not sure what main is. Please help me. I really want to get this running again and ride it.

Can I remove the engine kill switch? What wires do I need to cut?

Hello, eugrub, and WELCOME to KZr! :cheer:

Click this link for a wiring diagram download from KZr's FILEBASE.

www.kzrider.com/filebase/doc_download/36...z750m1wiringdiag0002

Good Fortune! :)
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Last Edit: 2 years 7 months ago by Patton.
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fuse keeps blowing everytime I kickstart - HELPpls 2 years 7 months ago #517052

Check wiring to the coils - If I understand this correctly the fuse is only blowing when the engine is turning (via kicker) and producing power? Are you getting spark? Does the electric start not work?

I would strongly advise against cutting any wires - you need to track down where the short circuit is. Look for a short in the main circuit, possibly even in the kill switch/starter switch area. Previous owner could have accidentally pinched a live wire in the switch assy. against the handlebar, causing a massive short - I have had this happen before - took me awhile to track it down.

Be looking for things like this. I just solved a shorting issue with my coils - see post "1976 Kz900 A4 blowing main fuse" for some good advise from other members of the board. Unfortunately our wiring will definitely be different.

Good luck
76' KZ900
00' KLR650
82' XV920 Virago
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fuse keeps blowing everytime I kickstart - HELPpls 2 years 7 months ago #517069

  • Motor Head
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Maybe its on your Charging system. The Charging system only creates voltage when the engine is turned. So maybe you have a pinched wire under your sprocket cover? Just a thought.
Also the Pick up coils for the electronic ignition would create a small voltage signal when the engine rotates, for the ignitor to make spark. So check the wiring from the Ignition pick up coils to the ignitor a swell.
1982 KZ1000LTD K2 Vance & Hines 4-1 ACCEL COILS Added Vetter fairing & Bags. FOX Racing rear Shocks, Braced Swing-arm, Fork Brace, Progressive Fork Springs RT Gold Emulators, APE Valve Springs, 1166 Big Bore kit, RS34's, GPZ cams.
1980 KZ550LTD C1 Stock SOLD Miss it
1979 MAZDA RX7 in the works, 13B...
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fuse keeps blowing everytime I kickstart - HELPpls 2 years 6 months ago #518152

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Hi all, fuse was blowing up every time I turn on and have killer switch at RUN position. I found out I plugged one wrong wire to Negative. I removed it and fuse doesnt blow anymore. I tried to start it but I get no sparks. I took the coil out and brought it to dealership to test it to see if it is good and it is no good. I bought OEM coil from Ebay for $80 (rip off, I know). I put it on today and still get no spark. I also replaced regulator. Maybe stator is bad? I hope not! This is really frustrating. I wish I never removed wires and leave it like that.

Also, theres two wires (yellow with red and yellow with blue) which one of them goes to + and - on coil?

I can take pictures if that helps
Last Edit: 2 years 6 months ago by eugrub.
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fuse keeps blowing everytime I kickstart - HELPpls 2 years 6 months ago #518156

Take a look at your points... Take the cover off the right and try starting it if u don't have spark their ur points are bad I went to the dealer to get mine that was the cheapest place eBay wanted double the price they should be around 13-14 bucks
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fuse keeps blowing everytime I kickstart - HELPpls 2 years 6 months ago #518164

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eugrub wrote:
Hi all, fuse was blowing up every time I turn on and have killer switch at RUN position. I found out I plugged one wrong wire to Negative. I removed it and fuse doesnt blow anymore. I tried to start it but I get no sparks. I took the coil out and brought it to dealership to test it to see if it is good and it is no good. I bought OEM coil from Ebay for $80 (rip off, I know). I put it on today and still get no spark. I also replaced regulator. Maybe stator is bad? I hope not! This is really frustrating. I wish I never removed wires and leave it like that.

Also, theres two wires (yellow with red and yellow with blue) which one of them goes to + and - on coil?

I can take pictures if that helps

Coil's primary terminals are non-polar.

Presupposing that the correct two wires are being attached to the coil primary terminals, it doesn't matter which wire is connected to which terminal.

Good Fortune! :)
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fuse keeps blowing everytime I kickstart - HELPpls 2 years 6 months ago #518206

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Thanks Patton. What do you mean by points? You mean spark plug point? I bought two new spark plugs and still getting no spark
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fuse keeps blowing everytime I kickstart - HELPpls 2 years 6 months ago #518346

Get a manual and a multi meter from walmart man itll be the best collective $40 youve ever spent, maybe better than that OEM coil you bought. Z1 sells coils fairly cheap.

Doesnt the 82 have pick up coils guys?

Also how are you checking for spark?

Did you reground your battery to the frame after you took your whole wiring harness out? I pulled this and it stumped me for a week, I felt like and idiot for sure :P
Keep it together man!

79 KZ650 "Geto Cycle"
Last Edit: 2 years 6 months ago by munkybrain2010.
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fuse keeps blowing everytime I kickstart - HELPpls 2 years 6 months ago #518351

Congrats on the bike but it's no fun if you can't ride it. :silly:
Was this bike running when you got it?
As munkybrain asked: how do you know it's not getting spark?
Do you have a starter on the bike? If you aren't getting fuel or something is outta whack in the fuel or spark areas you are going to have a hell of a time starting that bike by just kicking it.
Anyhoo... You have a couple of options to check for spark here:

Pull one of the spark plugs and then put it back into the socket on the end of the spark plug wire and then rest the end that normally goes inside the engine against the engine case. I wouldn't recommend holding it there with your hand, just let it rest there by gravity. Now try to start the motor. If the plug is touching the engine casing sufficiently (grounded) you will see a spark. If you do see spark then you can re-install it in the engine and move on to the next possible cause.
The other option is to grab a can of starting fluid and spray it into the airbox or filter whichever you have and then try to start the bike. If it fires up even momentarily then you got spark but most likely you also have fuel or fuel/air issues.
But, first things first. Check for spark and let us know!
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fuse keeps blowing everytime I kickstart - HELPpls 2 years 6 months ago #518352

  • saxonpirate
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If you haven't got one I'd definitely get a service manual and a multi-meter as Munky suggests. Some meters have a continuity tester that buzzes or bleeps to show a circuit/wire is continuous and ok.

At the moment you are just stabbing in the dark and need to isolate the problem, you'll end up replacing the whole bike otherwise. Do all the other functions of your bikes electrics work as they should...lights, flashers, horn. If they do you can at least discount a problem there.

Try and get hold of a wiring diagram for your ignition circuit. If there's one online zoom in and take some screen shots of it and methodically go through all your connections on the bike. Check your colour coding of the wiring...

You say you bought a harness off Ebay...just maybe there's a break in that harness somewhere. It's gonna be an old harness, not new, so its a definite possibility. Don't discount it, check the continuity of that wiring and then the connections.
1983 KZ1100 LTD..

Ride like your life depended on it :-)
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fuse keeps blowing everytime I kickstart - HELPpls 2 years 6 months ago #518353

  • PRM068
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I have a 1982 KZ1000 LTD.

A couple of months back i had a similar problem. The main fuse for ignition kept blowing - the big bugger....30 amps or something.

From memory, I just went through all the connections and found that there was some serious corrosion appearing in the various connectors. I also ensured all my earths were good, but generally, just made sure all connectors were clean. If you trace all the wires and they are all making good contact, then it must start. I even pulled the ignition switch wiring apart and did that.

Peter
1982 KZ1000 LTD
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fuse keeps blowing everytime I kickstart - HELPpls 2 years 6 months ago #518413

  • eugrub
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I never took the ground wire out at all. I will be going to Wal mart and buy multi meter and start working on it all day. I removed one of spark plugs and lay it against the engine case and kickstart but getting no spark. My bike doesnt have starter since last owner made it kickstart only. If I have a spark, it will run for sure! So frustrating. I will keep you guys updated tonight. Thanks guys for your help. I really appreciate it!
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fuse keeps blowing everytime I kickstart - HELPpls 2 years 6 months ago #518415

Great. I agree wholeheartedly with everything that's been advised so far. You just had to do that one test to make sure what direction to go. Sounds like you have a "custom" bike so there are a lot of variables here that we won't know about so we will rely on your observations. We don't know your skill level, being methodical and compartmentalizing your effort will save a lot of time and frustration so bear with it.
Answer a few quick questions for me:
So, the fuse no longer blows now that you corrected the mis-wire at the RUN/STOP switch, right?
What harnesses are missing?
Was the harness you purchased new or was it an original (used, I mean) and possibly ratted up? Be honest, we don't care, we just want to see you riding your bike.
What kind of ignition system do you have? On the right side of your engine there is a round cover that's held on by two screws. Remove that cover and tell us what you see (or take pictures).

Verify the health of your harness as Peter suggested.
With the tank off and everything hooked up and the ignition switch on, the RUN/STOP switch in the RUN position, use your meter to find the voltage at the small wire on the coil.

Think of this as an opportunity to learn!
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fuse keeps blowing everytime I kickstart - HELPpls 2 years 6 months ago #518429

  • eugrub
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Who knew multi meter will save my time? WOW! I found one wire that isnt connected right. Now I found other harness that is belonged to it but I have no idea where it is going to. Just that one wire. Heres some pictures to clarify. Pictures tell you better than my words.









Any idea where is #2 should go? Can I remove #1 wire and rewire from #2 to #2 but where is it going to? What about "?" wire? FYI I dont have starter
Last Edit: 2 years 6 months ago by eugrub.
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fuse keeps blowing everytime I kickstart - HELPpls 2 years 6 months ago #518430

  • eugrub
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Killer switch is stop/run switch sorry
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fuse keeps blowing everytime I kickstart - HELPpls 2 years 6 months ago #518433

  • MFolks
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On the kawasaki's, any wire that's BLACK with a Yellow stripe, is a ground circuit wire, or should be connected to a ground. The battery Negative(-) cable goes to an engine mounting bolt, and that's sground wire too.
1982 GPZ1100 B2
General Dynamics/Convair 1983-1993
GLCM BGM-109 Tomahawk, AGM-129A Advanced Cruise Missile (ACM)
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fuse keeps blowing everytime I kickstart - HELPpls 2 years 6 months ago #518434

  • eugrub
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ok so where should i connect ? to? any ground?
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fuse keeps blowing everytime I kickstart - HELPpls 2 years 6 months ago #518435

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If the wire in question is coming off the battery Negative(-) terminal, it's a place for another circuit to connect for a ground. Do you have a wiring diagram? If so, it will make troubleshooting much easier.
1982 GPZ1100 B2
General Dynamics/Convair 1983-1993
GLCM BGM-109 Tomahawk, AGM-129A Advanced Cruise Missile (ACM)
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