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1983 kz750 f1 4-cyl no spark, good parts. 21 Feb 2024 21:22 #895513

  • LeftyFix
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Good morning all, recently I’ve been at a standstill with a kz750 that had been acquired as it “just needed a starter” (had to replace starter clutch, did so successfully) now that it turns over, I realized I have no spark on any of the plugs. 
at this point, I’ve replaced the ic igniter and pickup coils with oem tested working parts. Had a pretty bad old batt in it so replaced that with a new one.
Still no spark on any of the plugs. Ran through the clymer manual diagnostic for the ignition and can’t seem to figure it out and I’m at a loss (and not particularly savvy with electrical work, along side wrong wire color splices from previous owners)
any advice is welcome. 

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1983 kz750 f1 4-cyl no spark, good parts. 22 Feb 2024 10:46 #895523

  • OKC_Kent
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Did you test your coils? 
 
Oklahoma City, OK
78 KZ650 B2 82,000+ miles

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1983 kz750 f1 4-cyl no spark, good parts. 22 Feb 2024 11:41 #895524

  • Wookie58
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Have you checked you have battery voltage at the coils from the kill switch when the ignition is on 

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1983 kz750 f1 4-cyl no spark, good parts. 22 Feb 2024 15:27 #895527

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It appears I do not have voltage going to my coils, possibility of a short in the kill switch? Might not be connecting the black probe to the right bit, not sure if I can just ground it anywhere. No difference with kill switch and ignition on and off

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1983 kz750 f1 4-cyl no spark, good parts. 23 Feb 2024 04:15 #895541

  • Wookie58
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Carry out the below voltage checks and let me know how you get on, we can then look at next steps

 
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1983 kz750 f1 4-cyl no spark, good parts. 25 Feb 2024 18:37 #895593

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A 0.20vB 0.20vC 10.09vD 0v

sorry for the late response, been ultra busy with work. Took me a minute to figure out the ignition switch connector was inside the headlight shroud too lol

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1983 kz750 f1 4-cyl no spark, good parts. 25 Feb 2024 22:54 #895598

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The difference between "B" and "C" would suggest the kill switch is faulty however the 0v reading at "D" doesn't make sense as this supply's "C" 

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1983 kz750 f1 4-cyl no spark, good parts. 26 Feb 2024 10:09 #895611

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Is there any way to bypass the kill switch to test this? I’ve bought more parts trying to fix this issue than I’m proud of, and I don’t get paid until the end of the week for more.
or cheap replacement/rebuild advice.
could I bypass the kill switch to test? See image below for what I mean
 
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Last edit: by LeftyFix. Reason: Addition

1983 kz750 f1 4-cyl no spark, good parts. 26 Feb 2024 10:47 #895617

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Yes you can, I would suggest poking your bridge in the back of the multiplug and using a fuse in the bridge (just to be safe) On the upside you can sell all the parts you replaced that didn't fix it and recover some of your spend 

If it does turn out to be the kill switch you could try taking it apart, clean the contacts with 400 wet and dry and apply a smear of dielectric grease which will at most cost a tube of grease
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Last edit: by Wookie58.

1983 kz750 f1 4-cyl no spark, good parts. 26 Feb 2024 11:11 #895619

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Will try later tonight and let you know the results, thank you for your help this far, if for nothing else than making me learn a bit more about electrical work
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1983 kz750 f1 4-cyl no spark, good parts. 26 Feb 2024 16:42 #895633

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The kill switch was indeed the issue! Shorted the red and yellow wire in the kill switch connector and it gave me power to the coils and spark! Enough to make it sputter with ether, and make me realize i forgot to replace the exhaust gaskets on the headers. 
going to disassemble the kill switch at some point in the future and see if I can’t clean it up a bit, but just to get it running I will call this a great success. Thank you for all your help and I wish you ease in fitment of all of your future modifications.
 
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