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1978 KZ650 problems
- k0ba1t
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I was told i may have a short or something, fuses are good. there is one wire that i think may be trouble, but i need some more experienced opinions.
k0
1978 kz650c matte black. Current project.
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- k0ba1t
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1978 kz650c matte black. Current project.
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- MFolks
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The Dreaded Shorting/Intermittent Electrical Problem!
Here is the most basic method I know(Taken from www.kzrider.com by member Patton)
1. Charge your battery and have it load tested if you can. The floating ball hydrometer can be used to check the specific gravity of the charged cells in the battery.
2. Disconnect the Black lead from the (-) Battery terminal... or Red from the (+) Battery terminal, it does not matter which one. Just 1, not both!
3. Connect one of the following test setups in series with the Battery terminal and lead:
3.1 A 12 V light bulb,
3.2 A 12 V test light,
3.3 A 12 V test buzzer or,
3.4 A 12 V horn... you get the idea.
4. With the Ignition Switch OFF, go through your harness and wiggle the wires while looking/listening for the test setup to go on/start buzzing.
5.With the Ignition Switch ON, repeat the test except this time the looking/listening for the test setup to go off/stop buzzing.
6. Be prepared to open the Ignition switch and check/test for solder joint failure and or circuit board micro breaks (don't ask how I know this ).
7. Be prepared to pull the wires out of the Head Light to test for failures at or near the grommet.
8. Be prepared to open the harness at or near the Steering Neck for failures. This is where wires tend to exhibit fatigue due to repetitive movement.
9. Be prepared to open the left and right switch gear to search for rust and or broken parts. CAUTION: watch out for flying springs, ball bearings and stuff. Do indoors on White sheet (again don't ask ).
10. Be prepared to follow the heavy gauge wire from the Starter Solenoid (Relay) to the starter for bare wire exposure. Especially near bends and grommets.
11. If you can reproduce the fault symptom your are pretty much home free. Be prepare to find and repair/replace any internal wire breaks, insulation break downs, exposed wires, rubber grommet failures, etc. Often, shrink tubing will solve the problem temporarily until something better can be done.
12. I use a very good electrical contact cleaner/preservative called De-oxit made by Caig Labs in San Diego Ca. Their website is www.deoxit.com It can be purchased at Radio Shack and any other electronic supply store. I use it on all of my motorcycle’s electrical connectors , in my home entertainment center’s stereo patch cords and cordless phones charging cradles.
Verify that fron the Negative(-)battery post/terminal, a heavy gauge cable/wire goes to an engine mounting bolt. From the Positive(+) post/terminal, another cable/wire goes to the starter solenoid, from it a similar cable/ wire goes to the starter motor.
1982 GPZ1100 B2
General Dynamics/Convair 1983-1993
GLCM BGM-109 Tomahawk, AGM-129A Advanced Cruise Missile (ACM)
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- k0ba1t
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k0
1978 kz650c matte black. Current project.
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- elfmagic17
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k0ba1t wrote: if i connect the battery in any way, then the wires start to smoke. so i wouldnt be able to do this. Unless i am not understanding how to hook it up. if i am thinking correctly, it is + lead >> test item >> + terminal, correct?
k0
You put the Bulb,test light,buzzer,horn (let us call this the Load) in between the cable and post, it finishes the circuit. When you wiggle wires and find the short the bulb goes off,buzzer stops, horn stops, (load goes away) you get the idea. Key has to be off since it happens with nothing on.
Kenny
Kenny Hicks
74 Honda CB550
75 Honda CB360 (runs and rides good but not a show bike)
77 KZ650B1 (Runs Great, but needs painted and a little work.)
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- k0ba1t
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k0
1978 kz650c matte black. Current project.
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k0
1978 kz650c matte black. Current project.
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- Motor Head
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- FIX UP YOUR BIKE RIGHT AND CHEAP
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If that checks out, unplug the red/white wire from battery + to Regulator/ Rectifier. Try it again, if still heating pull the fuses, starting with the Main fuse. Try again, etc. If you see a big spark when you touch the cable to the post there is a short or something turned on. If something is on, it shouldn't heat up wires. Only a short should be able to do that. You may have a defective R/R, or maybe you pinched a wire when changing the battery. Any wire with Black/ yellow should be -, take a picture and post it. Some times that helps show an incorrect hookup.
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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- k0ba1t
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I probably created this problem when i reverse installed the battery the first time. so a new harness looks the way to go.. is an '81 harness the same?
1978 kz650c matte black. Current project.
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- Motor Head
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If you are asking if a 81 harness is the same as a 78, you would be very lucky to find a harness that is the same with 4 years between. Also more info of each would be needed. Best to find out whats burned/ melted and then decide if its fixable or a new harness would be best. Most of the wiring terminals can be bought new, and wires can be replaced.
Ebay is probably the best place for a harness, but a member here may have one as well. Maybe post a wanted to buy here and see if anyone can help out.
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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1978 kz650c matte black. Current project.
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- k0ba1t
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My question now is what could have been the cause of this? Bad ground?
1978 kz650c matte black. Current project.
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