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Premium Member
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741 Posts
Discussion Starter #1
now thats was a fun ride tonight :(

started the bike fine, warmed it up and as i take off i hear like something snapped underneath. the bike is still running but when i let off the gas to engine brake headlight dims. as i accelerate i notice RPM needle jumping allower the tach, i let of the gas the bike dies.
i enjoyed walking the thing half block back home and pushed it into garage. removed the seat and see the ground wire snapped of the battery but still intermitenly touching the contact. :doh:
WTF?! during winter i went over the entire wiring, cleaning contacts, searching for the problem that almost got me stranded near Dubuque IA last summer and didn't notice something obvious like this?! since the bike spent the winter in attached garage i didn't completley removed the battery, just the positive contact... shame on me...

oh well, at least it happened close to home and i don't think i could have fried R/R that fast...

off to autozone for a new ground wire.
 

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and the Adventure Cycle
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6,141 Posts
:doh: Don't it feel good though when ya realise it was something so simple !
 

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Premium Member
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741 Posts
Discussion Starter #4
How in the crap did it snap? Freakin weird.
the ring obviously remained bolted to the battery contact but the rest of it broke near the crimp to the actual wire was just hanging touching the battery contact :wow: when i replaced the batery last year it looked fine.

i'm not sure about exact milage but i filled 3 tanks of fuel already this season. i couldnt posibly ride like this all this time. or could i ... :doh:

hyper,
it sertainly does feel good :D

and another very interesting finding from last night - despite perfectly level appearance, our street is NOT level at all! :lol: felt every slightest (even the invisible ) inclines and declines walking the bike home.
 

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Registered
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126 Posts
when disconnecting a battery you should disconnect the ground side not the positive (if your gonna be lazy and not do both). I am not certain the rationale but thats what my mechanic friend does. one rationale is of course you wont fry yourself if your wrench accidently hits the frame that way!
 

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Premium Member
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741 Posts
Discussion Starter #7 (Edited)
went to Chicagocycle again to see if they might have the factory negative wire. first i thought to just put new terminator on the old one but it would have been too short. actually it is very short as it is which i think was the reason it snapped. it took over 15 minutes for the morons at CCC to find out that they don't have that in stock and if they had they would ask 20$ for it. what?! 20 for a piece of wire?
"20 dollars?! but it is just a wire!"
"it is a factory wire from Kawasaki..."
"but it is still nothing more then 3 inch piece of electrical wire!"
"hmmm... no, it has kawasaki boots on it too!" :BLAM:

so i went to wall mart and got general porpuse "Lawn and garden" 19 inch negative cable instead. it is even biger gouge then the original. i was kinda conserned how the extra lenght will fit in there but was able to route it very niceley. the original harness had another wire going from the ground and i had to cut from the old cable, put a ring teminator on it and give it separate mounting point as it was couple millimeters short of reaching standart point.

it all seemed fine but the new problem that i have now is intermittent starter operation :doh: basically sometimes as i'm pushing the starter button to fire the engine up nothing happens... i would turn the key on and off couple times and she fires right up... arrrgh. i'm going to go over the wiring again paying particular attention to the disable switches and he like

can anyone think what else could prevent starter operation?
 

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Premium Member
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4,054 Posts
Tank, this might be a longshot, but my 80 550 actually had a starter button go bad. It did the same thing, only after several tries did it seem to make contact and fire up the bike. I was just getting ready to pull it off and clean it up one weekend and a couple days prior, I went out to go home for lunch and the button was gone! Had broken and it and all the guts were somewhere on the road. I had to hotwire it, and drove it that way a few weeks until I got a new set of right controls off ebay. Might not be related, but mine was doing the same as yours prior to busting.
 

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HAWK
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2,576 Posts
Could also be the contact on the ignition switch.
 

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Registered
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126 Posts
id hook your Voltmeter to the battery and see if you get a drop when you press the starter button, might give you a clue as to what side your problem is. if you get a big drop but your starter doesn't turn-- then its probably a short in the starter - if you don't register any change, then perhaps your button is just broken.
 

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Benjammin'
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421 Posts
I have heard that our bikes, with age, the key switch will go bad. A wrench said to squirt WD40 into the keyhole and work it a couple of times. Since I heard that, I now use the run switch to shut the bike off to prevent arcing inside the key switch. Maybe paranoid- maybe fact???
 

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Premium Member
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741 Posts
Discussion Starter #12
thanks all for the input, i personnaly suspect the ingnition switch, going to open it up...

today everything worked like a clock, not a single mis-start :BLAM: go figure...
 
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