Buddy of mine has a 1978 KZ650 with some strange electrical issues. The starter is always hot even with ignition and kill switch off. But even though the starter will engage at anytime it wont start unless you....
Hit starter button and then while cranking turn the key on! If you turn the key on and then hit the starter button it will crank but never fire. (clutch switch is bypassed)
Today we set out to figure why the starter button is always hot and found some wiring is wrong by the schematic we have.
The
red/yellow wire off the starter relay was tied to a hot wire straight off the battery and then tied into the
red/white wire that runs from the rectifier to the 20A fuse.
The schematic we have shows that the
red/yellow wire from the starter relay goes to the
black/yellow wire. The black/yellow wire is the main ground for everything correct?
So we went about changing these wires to be how the schematic shows. Then the starter, kill switch and ignition switch all worked like normal. Problem solved we figured. Well, after a few mile test ride the bike died, completely dead battery. After jumping the bike we checked and have no charging at the battery. We put the wiring back how it was and now its charging. ???? I'm kinda stumped here, anyone have any idea what could be going on?
It looks to me like the
red/yellow wire off the starter relay should go to ground thru the
yellow/black wire. But if I do that then I get zero charging with the bike running even though then the ignition switch works like it should.
Any ideas on what to check next?