1980 Z1R Low beam, high beam indicator, head lamp warning, hazard issues

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12 Mar 2022 13:21 #863658 by 1980 Z1R D3
Hi guys, I'm a bit perplexed by my issues and was hoping to get some advice on my next step. 
My Z1R has some strange electrical issues and I'm not the best at electrical to begin with. First off, the headlight low beam, which should be on every time the ignition is on, is not. The head lamp out light is lit up on the dash, however, if you switch it to high beam, the high beam comes on. The high beam indicator light however, does not come on. It seems like a very weird combination of things going wrong that seems rather contradictory. Also the hazard switch does not work, but the turn signals do. Ive had that issue before and replaced the relay and that fixed the problem, but it now isnt working again. I took off the headlight/turn signal switch and was able to get the high beam to come on by using a piece of copper wire to complete that circuit, but couldn't get the low beam to come on. I replaced both the headlight and the high beam indicator switch bulbs, but they still wont come on. I'm just kinda stuck. I also don't really understand the wiring diagram, particularly the switch for the headlight and turn signal. I have attached the wiring diagram. Just looking for advice on what to do next. 
Thanks, Colin



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12 Mar 2022 16:09 #863669 by Wookie58
Hi Colin I see from your profile the bike is a D3 model. I am assuming it is a US/Canada spec. That being the case I have had a look at the wiring diagram and the US spec bikes have quite a complex lighting system, it’s late now in the UK but in the morning I will put a test plan together for you. Do you have a voltmeter and are you comfortable with it ?

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13 Mar 2022 03:08 #863690 by Wookie58
Good morning Colin. I have had a look at the manual (in the "articles" section) this morning and there is extensive information for testing the lighting system from page 291 onwards. This system is complex with "bulb failure" and "substitute" lighting functions etc as well as complex self cancelling indicators. I would suggest working through the factory testing sequence as I am sure any of these electrical parts will be hard to find and expensive if faulty (the European models didn't have this stuff so "US only") so you don't want to "misdiagnose" or "take a guess" 
Kawasaki KZ 1000 (A2A-A3A_MKII-A4-D3_Z1R) '76 thru'79 - Service Manual.pdf (kzrider.com)
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13 Mar 2022 10:20 #863708 by gd4now
Not sure if this will be of any help to you or not.  I find it easier to follow a color wiring diagram than a black and white one. Here is a color one for the D3.

1977 KZ650 B1
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13 Mar 2022 10:39 #863711 by 1980 Z1R D3
You dont happen to have a higher quality image do you? I find I cant read that one.



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13 Mar 2022 10:42 #863712 by 1980 Z1R D3

Good morning Colin. I have had a look at the manual (in the "articles" section) this morning and there is extensive information for testing the lighting system from page 291 onwards. This system is complex with "bulb failure" and "substitute" lighting functions etc as well as complex self cancelling indicators. I would suggest working through the factory testing sequence as I am sure any of these electrical parts will be hard to find and expensive if faulty (the European models didn't have this stuff so "US only") so you don't want to "misdiagnose" or "take a guess" 
Kawasaki KZ 1000 (A2A-A3A_MKII-A4-D3_Z1R) '76 thru'79 - Service Manual.pdf (kzrider.com)

Thank you Wookie, that will be my plan going forward. I do have a voltmeter and Im fairly comfortable with it. This is quite the perplexing problem so I'll be eager to go through the factory testing sequence and see what I can find out. Yes parts are expensive and rare so Id rather not throw money at the problem so I'll take your suggestion. It is a U.S. spec, my father knew the guy who bought it in 81.
 



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13 Mar 2022 10:42 #863713 by Wookie58
Hi gd4now, colour is definitely easier to follow for sure. I think the challenge with this one is the complexity. The system uses reduced voltages for bulb substitution etc and the warning lights also operate at different brightness dependent on what is occurring, therefore you need to really be "on it" to interpret your test results and not end up replacing rare and expensive components unnecessarily, I still think the best bet on this one is to follow the manual as it guides you as to what results to expect (IMO) 

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13 Mar 2022 10:46 - 13 Mar 2022 10:47 #863714 by 1980 Z1R D3

Hi gd4now, colour is definitely easier to follow for sure. I think the challenge with this one is the complexity. The system uses reduced voltages for bulb substitution etc and the warning lights also operate at different brightness dependent on what is occurring, therefore you need to really be "on it" to interpret your test results and not end up replacing rare and expensive components unnecessarily, I still think the best bet on this one is to follow the manual as it guides you as to what results to expect (IMO) 

I wasn't aware of the fact the brightness has a meaning Wookie but great to know, I'll take a look at it when I get back home this evening and update you as I go along.
 



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13 Mar 2022 11:10 - 13 Mar 2022 11:12 #863717 by Scirocco
I can offer you a colored higher quality wiring diagram.

 
 
Last edit: 13 Mar 2022 11:12 by Scirocco.
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13 Mar 2022 11:46 #863722 by gd4now
I agree the testing procedures of the system in the manual should be used to find the issue. As I said I find it easier to follow wiring diagrams in color than in black and white. Not trying to say a pic of the wiring system provides much more than just a pic of it.  

I currently do not recall where I got that pic from, but do not have a bigger version of it, sorry.  I know that I have had a much easier time making pics smaller than making them larger. without losing focus.

 

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13 Mar 2022 11:52 #863725 by Wookie58

I agree the testing procedures of the system in the manual should be used to find the issue. As I said I find it easier to follow wiring diagrams in color than in black and white. Not trying to say a pic of the wiring system provides much more than just a pic of it.  

I currently do not recall where I got that pic from, but do not have a bigger version of it, sorry.  I know that I have had a much easier time making pics smaller than making them larger. without losing focus.

Thanks, no idea why they chose to make the US spec so complex. I guess the Japanese do love a gadget 

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13 Mar 2022 12:24 #863729 by DOHC
I just scanned the FSM wiring diagram.  I should show up as an attachment to this post. 
I saved it as a PDF so that this site would not reduce the image size (as it does with JPG files).  It was scanned at 600 dpi so all the detail should be there.

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