Problem with '78 KZ650 auto start and looking for manuals

I just got a 1978 KZ650 and have a problem. I'm looking for a little
help. I'm a novice here and not very mechanical, so, bear with me.
Mostly I'm looking to isolate the affected parts so I don't get
screwed if I have to take it to the shop.

The 650 has both kick and auto start. The kick start works ok, but I'm
getting bruises from the kick start <g> and I'm basically lazy. I
learned on a KZ440 which only had the autostart.

During a tune up, the guys had a little extra time so they did a
little diagnosis. They determined that the switch itself is ok, so
there must be some other problem down further, short, etc. Anyone have
any thoughts or advice?


Also, anyone have the original Kawasaki service manual or owners
manual they would sell or copy? Kawasaki doesn't sell them anymore.



Thanks,

Kevin

kcblack(at)att.net

 

Notice that you never actually specify the problem you are experiencing.
I'm pretty sure it's that your KZ650 won't electric (auto) start, but
that is only the beginning. Is there any response of any kind to pushing
the starter switch? Does the starter spin the engine at all? Do lights
dim? Are there any noises? The more you tell the easier it will be to
offer advice.

You'll have better luck with thrid party manual suppliers such as Clymer
(http://www.clymer.com) and Haynes (http://www.haynes.com) both of
which list your bike in their lists of currently available manuals.

 

Sorry, I thought I put that in there, but essentially, nada, no
dimming,no noise no response at all to pushing the autostart button.

Thanks,

Kevin

 

Then one of two things is all but certainly true. Either the battery is
so dead that it may as well be removed or there is a fault in the starter
circuit or one of its components. We can probably eliminate the battery,
as its failure would be obvious from its effect on other electrical
sub-systems. But, to be sure, does the headlight work when you turn on
the main switch without the engine running?

If the battery is not at fault, that leaves the starter circuit or one of
its components. The starter circuit has primary and secondary parts. The
primary starter circuit consists of battery power via the main switch to
the starter switch to the starter relay. The secondary starter circuit
consists of power directly from the battery to the starter relay to the
starter. This arrangement prevents having to run the very large amount
of current required to operate the starter up through the main and starter
switches.

Given your report that there is no response whatsoever to pushing the
starter switch, one can conclude that the problem is probably in the
primary circuit or the starter relay because you would otherwise hear the
starter relay pull in. Diagnosis proceeds by measuring the voltage between
the negative battery terminal and various points in the starter circuit
when the main switch is on and the starter button is pressed. Begin at
the starter relay. If the battery voltage is present between the starter
relay's primary terminal and the battery's negative terminal when the main
switch is on and the starter switch is pressed, then the starter relay is
probably faulty and needs replacing. Otherwise, follow the circuit back
toward the starter and main switches until you find the battery voltage
when the main switch is on and the starter switch is pressed. The wire
or switch between where the battery voltage does and does not appear is
the fault.

Had you reported that you heard the starter relay click when the main switch
is on and the starter switch is pressed but the starter motor didn't turn,
then it would be appropriate to measure the voltages along the secondary
circuit.

There is one more possibility to consider. The negative terminal of the
battery is connected to frame and engine to form the "common" side of all
circuits. ("common" is often but incorrectly called "ground.") If this
connection is loose, dirty, or corroded, it can result in all electrical
sub-systems except the starter to work. This happens because the amount
of current required to turn the starter motor is much more than the other
sub-systems. You can eliminate this as the possible problem by ensuring
that the negative battery cable connections are clean and tight.

 

There are a couple of things about doing this that are worth mentioning.

First, when shorting the starter relay leads, do so with a substantial
conductor as a LOT of current is going to flow. There is enough current
to easily melt, for example, a 14 guage clip lead. A common approach is
to use a screw driver, but be sure to not touch it to the frame while
doing so!

Second, this short will bypass the transmission neutral switch and, if the
starter, battery, and secondary starter wiring are good, will turn the
engine regardless of whether the transmission is in gear. Put the bike
on the center stand to ensure it won't want to wander about the shop while
testing it!

Hey! There's another possible problem source. The trasnmission neutral
switch may have failed such that the interlock always prevents energising
the starter relay!

========================================================================
Michael Kesti | "And like, one and one don't make
| two, one and one make one."
| - The Who, Bargain

 

As I recall from my KZ650 there is a clutch safety switch. You might want to
disconnect it and jump the two wires together and see if you get some
starter action then. Also I am not sure about the neutral safety, but I
would think if the Neutral light comes on when in neutral then it is fine.

Also get a voltmeter and ck at the starter relay for ground at one of the
small wires. You should have one that has a good ground. Make sure to keep
the bike in neutral and the clutch lever pulled during all checks. Also ck
for power at the starter relay, (the small wires) when the starter button is
depressed, (and clutch pulled of course). If you are getting 12v when the
button is pushed then the low side is good and you should start checking on
the big wire side.
Ck your fuses, and connections for corrosion.
Good Luck