kz750 ltd h2 1981 engine wont crank problem

hi kz gurus!

we've been restoring a kz750 ltd h2 1981. the engine is newish, no rebuild necessary. it has only done 6,600 miles. the starter motor works and rotates with the battery. the main harness is from the same 6,600 bike.
we followed all the wires by colour coding and it's correct to the wiring diagram. the battery is new. the front and tail lights comes on. the ignition pilot light are lit, showing oil and neturns and neutral lights. the the front and rear brake lights work. the horn works. on turning the ignition key on and pressing the switch on, nothing happens? dead? the battery is fully charged

we've manually turn the engine. the plugs are out, there is no fuel connected at the moment. i just wanted to hear it crank before fueling up. safer!

this is a mystery, why wont the bike crank please?

many thanks

angela

sounds like you checked everything but the pushbutton for the start itself......that is where the problem may lie if you turn the key on and get all the indicating lights.....then that only leaves the starter button in the circuit that is not closing in.

There is a lock out switch on the clutch lever, pull in the clutch lever and try.

hi motor!

yippee!.. what a guru you're!

all as i did was to pull the clutch lever in and then press the starter, it crank!..

what is the purpose of the clutch switch please, safety?

the plugs are still out, my gas tank is still drying.

we should be able to start it soon!..

fingers crossed!

one inline fuel filter was offered to me for $12.86 in the uk! i've just ordered from Z1 6 x inline filters (for spares) delivered for $16, what a bargain!.. you're so much cheaper than the UK!

q) is it best to test for sparks now. do i just plug one into the ht lead, grip the lead with insulated pliers and touch it again a part of the bike please?
then repeat for the four? i've set my plugs to 0.07-0.08.

many many thanks! i'm getting my video camera ready for the first start up!.. fantastic.

regards

angel

Also assure kill switch is in RUN position.
Try again with sidestand up in ride position.

Edit -- Glad it's cranking over.

The mentioned test is a good way to check for spark on plugs. Hold plug base against engine head. Look for fat blue, not thin orange.

What plugs?? -- NGKB8ES?? -- Factory spec??
Would install brand new factory spec plugs and gap.

The many NGKB8ES plugs I've purchased over the years have been properly gapped right out of the box.

Good Fortune!

hi patton

many thanks my new friend!

you've so much knowledge.

on all the bikes that i've had, honda hornet, suzuki sv650.
they both had a side stand switch.
the kz750 ltd h2 doesn't have one mentioned.

we replaced the plugs to spec and also the ht leads.

i feel like i'm expecting a baby!.. the excitement is amazing. this is the first bike that my dad and i've built from scratch. the first bike i've totally wired up myself.

looking forward to testing the sparks tommorow.
i won't weld the engine will i, with the sparks?

where is the best place to touch the plug patton please?

good fortune back to you, superstar guru!

kind regards

angel
((( hug! )))

Wow....clutch lever interlock?.....my 440 doesn't have that.....neither does my honda shadow....

hi llp

many thanks for your messages.

having spent the last 12 months finding all the parts from the us. today is the day it's nearly finished.
i've just discovered a pointer off patton that this old dinosaur has a starter lockout switch. on pulling the clutch lever in it disengages the starter motor and allows the bike to crank. not pulling in the clutch lever, the bike appears dead!.. what a clever safety device!..

what bike do you've?

building your own bike is so rewarding, you know where everything lives and the kz, now! are easy to work on.
this all started with watching biker buildoff and OCC!
do you still watch them? i watch them all!..

best wishes

angel

The starter interupt switch is there to prevent you from trying to start it in gear.Cause that would be bad.It's ALLWAYS a good idea to start it in neutral anyways.Some bikes have the side stand switch,some don't.It's also a good idea to start it while sitting on it,with the bike in an upright state.Also,keep it on the center stand when parked.Don't let it run parked on the side stand,that could over load the oil to the left,and starve the right side of the engine.You could lay the plugs on the head and crank it over to check for spark.Just make sure you aren't part of the ground circuit,or it could be a shocking experiance.If you discover you have an oil consumption issue,it will most likely be from bad/worn out valve seals.Very common.Viton seals work best.Check E-bay for them.Good luck.

hi buddy

many thanks for your informative email.

for my sins this biker was trained by the uk police!
have you seen the size of a pan european bike!.. i'm only 5'6".

i've always used the main stand, rather than the side stand. being quiter a substantial weight, better for the kz!

kind regards

angie

Hi Angie,

Don't feel bad about the clutch lever switch, this Spring I de-winterized the 750, cleaned her up and she wouldn't start! Sat there for 15 minutes going through circuits until I remembered to pull the clutch in. Getting old is a bummer....

Not sure what the weather is doing over there, but don't run it stationary for too long without a fan blowing on the engine. Also, after the bike cools down the first time, check your torque on the head nuts, motor mounts, etc.

Good Luck!

angel_uk wrote:

...testing the sparks tommorow.
i won't weld the engine will i, with the sparks?
where is the best place to touch the plug....

Nope, no welding worries.

Just hold the base of spark plug firmly against the engine head, while spinning over the engine.

Is this bike easy to lift onto the center-stand?

Good Fortune!