Repalcing an ignition in 1980 ltd 650

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05 Sep 2013 16:34 #605050 by Kieran_z750
Repalcing an ignition in 1980 ltd 650 was created by Kieran_z750
A friend of mine lost his keys, ordered a new ignition online, but can't get the old one out. He removed all the headlights, turn signals, etc and exposed the ignition. It won't come out! After a while of angry pulling, he pulled the actual wires from the back of the face of the ignition. Now just the metal cap and casing remain in the bike. He hooked the new one into the bike, but it won't start still. The old ignition had 7 wires (a brown one is 7th and was outside the white rectangular housing) and the new one only has 6 (no external brown wire).

1 - how to get original ignition the rest of the way out?
2- do I need to get that brown wore hooked up for the new ignition to work?

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05 Sep 2013 17:04 #605055 by martin_csr
Replied by martin_csr on topic Repalcing an ignition in 1980 ltd 650
Did he try removing it from the underside? The diagrams at Kawasaki.com or Partzilla might be helpful (ignition switch & meters). His bike is different, but on my 81 650 I have to remove 2 allen bolts on the underside.

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05 Sep 2013 17:44 #605070 by MFolks
Replied by MFolks on topic Repalcing an ignition in 1980 ltd 650
That's the way it is on my 1982 GPz 1100 B2. Lower the headlight & the Allen head bolts are right there.

1982 GPZ1100 B2
General Dynamics/Convair 1983-1993
GLCM BGM-109 Tomahawk, AGM-129A Advanced Cruise Missile (ACM)

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05 Sep 2013 19:38 #605096 by martin_csr
Replied by martin_csr on topic Repalcing an ignition in 1980 ltd 650
His seems to be different. I can't tell from the diagram if there are any bolts that secure the switch.
There are a couple of tabs at the base of the ignition switch, and at the top there appears to be a retaining ring that looks like it should be unscrewed.
The following user(s) said Thank You: Kieran_z750

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06 Sep 2013 00:34 #605134 by Kieran_z750
Replied by Kieran_z750 on topic Repalcing an ignition in 1980 ltd 650
so here are a few photos i took this afternoon. the one called moto back 2 shows the ignition from the back with the wiring removed. there is just a metal casing still there that i can't get out. on the photo that says ignition top, shows the ignition top still in there. i tried to start it this afternoon and it seemed like it was close to starting, but now the electrical systems don't even go on when i turn the key in the new ignition. weird. any ideas?
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06 Sep 2013 00:37 #605135 by Kieran_z750
Replied by Kieran_z750 on topic Repalcing an ignition in 1980 ltd 650
yeah we've pretty much removed every bolt/screw in sight. no go. i'm looking at the wiring guides you suggested from the kawa site now. thanks for the suggestion.

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06 Sep 2013 00:43 #605138 by 650ed
Replied by 650ed on topic Repalcing an ignition in 1980 ltd 650
Did you unscrew the plastic ring on top around the keyhole and lift the idiot light cover off? Ed

1977 KZ650-C1 Original Owner - Stock (with additional invisible FIAMM horn)

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06 Sep 2013 12:31 #605195 by Kieran_z750
Replied by Kieran_z750 on topic Repalcing an ignition in 1980 ltd 650
I didn't think the black plastic ring came off. I've tried with my hand, wrenches, and pliers, but it hasn't budged. Is that supposed to come off? What is this idiot light you speak of?

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06 Sep 2013 14:20 - 06 Sep 2013 14:22 #605206 by 650ed
Replied by 650ed on topic Repalcing an ignition in 1980 ltd 650

Kieran_z750 wrote: I didn't think the black plastic ring came off. I've tried with my hand, wrenches, and pliers, but it hasn't budged. Is that supposed to come off? What is this idiot light you speak of?


Yes, it should just unscrew using your fingers, and then the cover just lifts off. Here's mine. Ed

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1977 KZ650-C1 Original Owner - Stock (with additional invisible FIAMM horn)
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Last edit: 06 Sep 2013 14:22 by 650ed.

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15 Sep 2013 22:35 #606614 by rstnick
Replied by rstnick on topic Repalcing an ignition in 1980 ltd 650
Should have given me the key code # and I could have cut you a key.

Rob
CANADA

Need a key for your Kawasaki? PM me

1978 KZ650 C2, 130K kms, Delkevic ex, EI, CVK32, PMC easy clutch, ATK fork brace, steering damper, braced swingarm, 18" Z1R front wheel.
2000 ZRX1100
2011 Ninja 250R
2005 z750s

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