I hate this freaking switch - Kawasaki Vulcan 750 Forum : Kawasaki VN750 Forums
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Where does this wire go?
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post #1 of 7 (permalink) Old 03-10-2018, 08:42 PM Thread Starter
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I hate this freaking switch

I've taken it apart ten times in 2 years and I'm convinced the switch itself is correct and clean. I've suspected the wiring, but never been able to force a break in the connection when testing. The only way I have ever had an issue, which continues through each year, is turning the handlebars and having the bike cut off on me.

Looks like I'll be replacing the wiring tomorrow. Without looking too far into the schematics what wires other than the yellow are involved in keeping the bike running.



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post #2 of 7 (permalink) Old 03-11-2018, 08:30 AM
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I had the same problem. The cover was missing so I replaced the complete switch. Best thing that could have happened ! No more problems. If I where You I'd change the complete unit,done.

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post #3 of 7 (permalink) Old 03-14-2018, 07:43 PM
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any wire contacting the frame or pinching and shorting to another wire could be suspect.
Unfortunately, you will have to check every wire look for any signs of chaffing or rubbing that could be the source of the problem.
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post #4 of 7 (permalink) Old 03-15-2018, 12:05 PM
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Try the wiggle test on wires where they plug together, and especially the Junction Box. The spades can get loose.

Check the wiring diagram to know which wires/plugs to concentrate on.

The spade was sloppy on the blue fan wire at the JB and was killing my fan. Just needed to pull the spade out and smash it a bit so it fit tighter. Found it with a wiggle test.

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post #5 of 7 (permalink) Old 03-15-2018, 09:28 PM
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Here's a simplified wiring diagram, it's the second pic. (.pdf file) https://drive.google.com/file/d/0B_V...9hMG5vQ1E/view

Check the white on pin 1 of the 8-pin JB connector.

I take it your dash lights go off/stay off when it dies or won't start?

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post #6 of 7 (permalink) Old 03-15-2018, 11:16 PM
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Here are the relevant wires you'll find at the switch, and in the wiring harness at the neck:

1. White wire is voltage going in for starter and spark.

2. White/black wire is voltage going in for turn signals. If you lose your signals along with the engine when turning, you're probably losing power on the white wire before the white/black gets T-d off of it. Probably hard to take note of as your bike dies under you on a curve. If your signals are good, your white might be bad between the T and the switch, or one of the following wires might be bad.

3. Yellow out to cutoff switch.

4. Red comes out of cutoff switch to ignitor box.

I would think that an open circuit is more likely than a short to ground since you aren't blowing fuses in addition to browning out/killing the engine, but there's no guarantee of that.
Are you able to get the bike to kill itself by turning the handlebar while it's up on the center stand?

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post #7 of 7 (permalink) Old 03-16-2018, 03:14 PM Thread Starter
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Thank ya! I'm an EE, but I'm stretched thin on time so I'm working lazy. I'll replace those wires. They have been wiggled and tested for 2 years. It's an intermittent issue so hard to get a reading at the right time. I'm over wiggling. I was going to replace all of them, but time again is an issue so I'll do the relevant ones back from the red plug to the switch.


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