Electrical Gremlins : Kawasaki ZX Forums: Kawasaki Ninja Forum

Shumaki · 08-28-2009, 03:48 PM

I am chasing a few elecrical gremlins in my bike. One of them is the headlight. There is no power at the connector where the harness plugs into the fairing for the high beam or the low beam. The parking lights and turn signals work fine.

The headlight fuse is good and there is power in the fuse box to the headlight circuit.

What do I check next?

Another gremlin is more critical. The engine starts and idles fine, but as soon as I let the clutch out it dies. It is as if you hit the kill switch- the engine dies before it is under load.

I tested the kickstand switch and it was bad, so I removed it and ran a jumper between the wires.

The engine dies as soon as the clutch lever moves the plunger switch on the underside of the handlebars. What is this switch supposed to do? I tried to unplug the connector to the switch. I did this when the engine was running. As soon as I put it in gear, it killed the engine. The starter would not work until I plugged the switch back in.

After plugging the switch back in, I used tape to secure the switch in the closed position (to simuate the clutch out). The engine would start, but it would die as soon as I but it in gear.

If I keep the PRMs up, I can get the bike to roll as long as I don't let the clutch out far enough to make contac with the switch.

Next, I started the engine, pulled the clutch in, put it in gear, and manually pushed the swith in WITHOUT releasing the clutch- and it died.

What is this switch supposed to do? The switch seems to be operating properly. What other sensor is not working right? Do I need to revisit the kickstand switch?

Shumaki · 08-29-2009, 08:49 AM

Well, these two gremlins are gone. The wires going from the sidestand switch to the main harness were bad. I bypassed them under the seat, closer to th emain harness and that problem is gone.

And as it turns out, when I was checking the headlight the engine was not running. When I tried it with the engine on, everything was good.

Claude · 08-29-2009, 11:25 AM

Quote:

Originally Posted by Shumaki

...The wires going from the sidestand switch to the main harness were bad. I bypassed them under the seat, closer to th emain harness and that problem is gone...

Glad to know you solved everything!
I also have an intermittent problem that I first thought the sidestand switch was the culprit. So, I bypassed it and the problem is still present so I deleted the switch from my list. However, reading your post make me believe I could have the same problem you had.

If you have a camera, could you please show me exactly where you by passed the wires? I could probably find it by myself but it would be faster with such a picture. Thanks!

Oh and do you know where the wires were bad? Maybe they were rubbing at a place that could be the same on my bike.

Shumaki · 08-29-2009, 05:52 PM

Quote:

Glad to know you solved everything!
I also have an intermittent problem that I first thought the sidestand switch was the culprit. So, I bypassed it and the problem is still present so I deleted the switch from my list. However, reading your post make me believe I could have the same problem you had.

If you have a camera, could you please show me exactly where you by passed the wires? I could probably find it by myself but it would be faster with such a picture. Thanks!

Oh and do you know where the wires were bad? Maybe they were rubbing at a place that could be the same on my bike.

I have a camera, but haven't figured out how to post pictures to the forum yet. I am a little slow out of the gate, so I wil try a detailed description to get you on the right track and maybe I will figure out how to post the pictures soon.

First off, I believe that my probem was the result of a fuel pump fire that occured before I bought the bike. several of the wires inder the seat area are a little crispy.

If you think these wires might be your problem, start the bike, pull the clutch in, put it in first gear, press the plunger switch on the underside of the left handlebar with your finger (do not release the clutch). If this kils the engine, there is some reason that the bike does not want you to ride- it may be the side stand switch.

The wires in question run from the side stand switch, behind the engine and into the main harness just in front of the battery. The easiest way to find them is to start at the switch and follow them up. On my bike when they leave the switch there is one green and one black wire. After about 8 inches there is a connectore plug where they become green/white and back/yellow. Shortly after the connector plug they are joined by a light green wire (neutral indicator light) that originates just in front of the oil sight glass. The three wires are taped together and snake behind the engine up to the main harness in front of the battery. Pull on one end and see what moves at the other. Obviously you will need to remove your seat. You will have much better access if you also remove your tank. I already had my entire fairing off so it was no big deal. If this is all you are doing you MAY be better off to just work around the tank.

On my bike, they used a fire extinguisher for the fire and then never cleaned off the powder. The powder is corrosive, so after sitting for a couple years some things don't want to come apart. I was afraid to pull too hard on the neutral indicator and I couldn't pull the side stand switch wires out without disconnecting the neutral light wire. It was faster and easier for me to just cut them close to the main harness and splice them together. I never did identify where the damage was.

I hope this helps. I am happy to answer any more quesions if I can. I will work on the picures.

miller511 · 10-12-2009, 12:46 PM

Hello all,

I'm new here. Great web site. Lots of good stuff. I hope I can add to the knowledge base here.

I bought a '96 GPZ 1100 in June that was not quite in running order. It had been sitting for a couple of years. Some wires had been chewed on from nesting mice under the tank!!! Fixed those and other issues...I think!!
Long story short- I finally was able to get most of the issues resolved except one that is almost exactly the same as what Shumaki describes. Hoping that it's as simple as the kickstand switch. Will check it out tonight. But, I also have trouble with the headlight not working? Were these issues related or independent for you Shumaki?

Thanks, Jeff

Shumaki · 10-13-2009, 07:06 AM

They were unrelated. Actually, there was nothing wrong with my headlight. I did not know it at the time of my post, but the headlight will not come on until after the engine is running.

miller511 · 10-20-2009, 09:45 AM

Shumaki,

Just a quick follow up. Success! I bypassed the side stand switch and the bike then ran great in gear. Also, put a new headlight relay in and still no headlight. Bypassed the relay and the headlight works. Maybe got a bad replacement relay?

After a couple of short rides around the neighborhood, was giving my GF a ride on the back...she's 115 lbs, when after only a mile or so, the clutch started slipping badly...she's 115 lbs. Nursed it back home at about 10 MPH. Seems to run OK with only one on board. Not sure what's going on with that. New clutch? Or maybe air in the hydraulic master or slave?

-Jeff