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KZ440-A2: Electrics are dead 03 Jun 2023 16:39 #885569

  • Wookie58
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Make sure you cut that white wire back to "clean copper" the green corrosion will continue and give you problems. Also stop measuring "ohms" voltdrop is a more accurate diagnosis of resistance faults (check out my fault finding guide in the FAQ section)
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KZ440-A2: Electrics are dead 03 Jun 2023 18:23 #885570

  • Nerdy
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(the best I could find to hand to offer a sense of scale was an old toothbrush!).
 

I keep toothbrushes around the shop as well: they're great for scrubbing small oily bits. :)
1979 KZ400 Gifted to a couple of nephews
1967 Yamaha YCS1 Bonanza
1980 KZ440B
1981 Yamaha XT250H
1981 KZ440 LTD project bike
1981 GPz550
2013 Yamaha FZ6R

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KZ440-A2: Electrics are dead 04 Jun 2023 09:22 #885595

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Hi folks.

I’ve sorted the 2 connections and tested the following. Still no electrics. 

battery is 12.9V
red/white from 20A fuse connects ok to +ve battery terminal
White from 20A fuse connects ok to White on 4P connector leading to ignition switch
Red/blue from ignition switch 4P connector connects ok to 10A fuse

the ignition switch in the On position still checks out ok. 

im stumped. Any suggestions please? 
1981 Kawasaki KZ440-A2

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KZ440-A2: Electrics are dead 04 Jun 2023 09:41 #885601

  • F64
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check the following:

key on
ignition on
engine not running
Meter on DC V

red probe positive battery terminal
black probe negative battery terminal
note voltage

do not disconnect the connectors--you will have to back probe the connectors to get your readings

move red probe to each fuse measure both sides..list voltages
red wire-red wire
red/blue wire-brown wire
blue wire-blue/white wire

And Warren3200gt's ground wire---
There is a black wire with a yellow stripe that connects to the negative terminal on the battery.
That ground controls a lot of the bike's functions
It should have a bullet connector on it close to the battery(pink circle).
Leave the bullet connector connected and back probe the connector with the red probe.
Reading should be a steady 0.0V.


 
81-KZ440-D2.
Louis Dudzik's GM HEI ignitor conversion installed 2015 s3.amazonaws.com/gpzweb/Ignition/GPZgmHEImod.html
Motogadget m-unit blue installed 2017.
LIC, NY
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Last edit: by F64.

KZ440-A2: Electrics are dead 04 Jun 2023 10:12 #885604

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Thank you.

responses in line below.

check the following:

key on
ignition on
engine not running
Meter on DC V

red probe positive battery terminal
black probe negative battery terminal
note voltage: 13.2v (I charged the battery again in the past 15 minutes. My previous post mentioned 12.9v)

do not disconnect the connectors--you will have to back probe the connectors to get your readings

move red probe to each fuse measure both sides..list voltages
red wire-red wire BOTH 13.2V. I DIDN’T REMOVE ANY OF THE FUSES. CORRECT?
red/blue wire-brown wire: both 13.2V
blue wire-blue/white wire: both 13.2V

And Warren3200gt's ground wire---
There is a black wire with a yellow stripe that connects to the negative terminal on the battery.
That ground controls a lot of the bike's functions
It should have a bullet connector on it close to the battery(pink circle).
Leave the bullet connector connected and back probe the connector with the red probe.
Reading should be a steady 0.0V. IM NOT SURE WHAT YOU MEAN, apologies. If I remove the red probe from the battery and use it, where should the black probe be connected? I’m also unsure what ‘back probe’ means? If the bullet remains connected, see photo, how do I get the multimeter probe to touch the metal?
1981 Kawasaki KZ440-A2
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KZ440-A2: Electrics are dead 04 Jun 2023 10:23 #885605

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slide the red probe under the clear rubber so it can contact the bullet connector.
backprobing means you leave the connector connected and you insert the probe in from the back.
Either of the pink arrows will work--it doesn't matter which side.
Your red probe should be able to touch the metal of the bullet conductor inside.

black probe stays on negative battery terminal

 
 
81-KZ440-D2.
Louis Dudzik's GM HEI ignitor conversion installed 2015 s3.amazonaws.com/gpzweb/Ignition/GPZgmHEImod.html
Motogadget m-unit blue installed 2017.
LIC, NY
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Last edit: by F64.

KZ440-A2: Electrics are dead 04 Jun 2023 10:39 #885608

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Thank you. 

yes, steady at 0.00V. 

Are the voltage readings at the fuses as expected please, in my previous reply?

 
1981 Kawasaki KZ440-A2
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KZ440-A2: Electrics are dead 04 Jun 2023 10:55 #885609

  • F64
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Your fuse voltages are good except there is no voltage drop on them.
This means nothing is using power.
If you turn a light on, the voltage will drop slightly to maybe 13.0v.
Your voltage is steady at 13.2 at the battery and the fuses which means nothing is on.
But it is good that your fuses are getting power now.

Inside your headlight bucket will be a 4 wire connector.
brown wire
red wire
white wire
red/blue wire

key on
ignition switch to "run"
meter DC V
all connectors connected

Backprobe the above connector
black probe on negative terminal
use red probe to check each wire on the green arrow side of the connector.



 
81-KZ440-D2.
Louis Dudzik's GM HEI ignitor conversion installed 2015 s3.amazonaws.com/gpzweb/Ignition/GPZgmHEImod.html
Motogadget m-unit blue installed 2017.
LIC, NY
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KZ440-A2: Electrics are dead 04 Jun 2023 11:01 #885610

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check this connector as well with the red probe(it should be in the headlight bucket also)
red wire
red/yellow wire
black wire----push starter button while checking voltage here--should go from 0.0v to around 13.0v when you push button
red/white wire

You should have battery voltage at all of the points. 13.2v or close

I'll be driving so I may not get to respond for a couple of hours.



 
81-KZ440-D2.
Louis Dudzik's GM HEI ignitor conversion installed 2015 s3.amazonaws.com/gpzweb/Ignition/GPZgmHEImod.html
Motogadget m-unit blue installed 2017.
LIC, NY
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Last edit: by F64.

KZ440-A2: Electrics are dead 04 Jun 2023 11:11 #885612

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No voltage on any of the ignition switch wires. 

I repeated it with a paper clip, just in case I wasn’t making contact. The depth of the connector is quite long. 

 
1981 Kawasaki KZ440-A2

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Last edit: by Jimbo68. Reason: Clarity.

KZ440-A2: Electrics are dead 04 Jun 2023 11:18 #885613

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Thanks. 

No such 4P connector for the  starter button, etc, on my bike 
 
1981 Kawasaki KZ440-A2
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KZ440-A2: Electrics are dead 04 Jun 2023 11:39 #885614

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I noticed when testing the voltage at the fuses that with the ignition OFF, the two 10a fuses remained at 13v. Only the 20A fuse dropped to 0V. 

is that expected?
1981 Kawasaki KZ440-A2

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