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1982 Starter Relay issues 23 Aug 2014 09:30 #644886

  • dwitek
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I replaced the original starter relay on my Son's 1982 Kawasaki KZ 440G with an aftermarket drop in unit. Wired as the directions said. I keep blowing the 30A fuse and the bike won't turn over at ll. I have all light, blinkers, horn and brake light functions though.

Can someone help me Please:(

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1982 Starter Relay issues 23 Aug 2014 10:43 #644893

  • 650ed
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I'm surprised your bike even has a 30A fuse. The largest fuse I see on Kawasaki.com is 20A (see image below). Definitely double check your installation instructions. The circuit that activates the relay should draw very little current, certainly MUCH less than 30 amps. Once activated, the relay completes the circuit between the battery and starter motor, and to my knowledge that circuit is not on any fuse. If you find your wiring conforms to the instructions I would call the relay vendor for support. Ed

Attachment 00003_2014-08-23.jpg not found

1977 KZ650-C1 Original Owner - Stock (with additional invisible FIAMM horn)
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1982 Starter Relay issues 23 Aug 2014 11:53 #644902

  • Motor Head
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  • FIX UP YOUR BIKE RIGHT AND CHEAP
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650ed is right. Do Not Use a Bigger Rated Fuse. You may well damage your wiring harness. When it blows the fuse it is telling you that the circuit is shorted directly to ground.
Your starter relay should have 2 large terminals with nuts, these are for the positive battery cable from the battery, and the other the cable to the starter. Then it should have 2 small wires. One to ground, and the other is from the start push button (power when button pushed).
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1980 KZ550LTD C1 Stock SOLD Miss it
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