1992 Voyager XII electrical problems

[bobberwi]

Hi All,

This is my first experience trying to use a help forum so my apologies if my protocol is poor and I sound like a mechanical dolt. Here is my situation/problem(s):

my motorcycle: [b]1992 Kawasaki Voyager XII

The bike is "fully loaded", i.e. stereocasette- AM/FM (Kawasaki/Clarion), 4 speaker, CB, passenger intercom with seperate contols, cruise control, trailer hitch with lighting wiring, aftermarket running lights.

I bought the bike via e-bay contact from a seller in TN. I traveled to Chattanooga to pick up the cycle 1 month ago to drive it back to WI (aprox 1000 mile trip). At the time I started my return trip home, the cycle seemed to function well... lights worked properly, radio worked, ignition switch worked, and cruise control worked. The horn did not work and the horn button switch did show evidence of distress as if someone had used a screwdriver to pry it. There was no "spring return" feel to it at all. I also noticed that the directional signal cancel function did not work (switch had to be manually returned to neutral position). I was also shown that a power cut off switch had been added (simple toggle switch in a faring compartment. I was told it was added as an anti-theft device. Later investigation revealed that the switch was to cut off power from battery to fuse box assembly.

...hints and indications of electrical system problems of a more complicated nature began to surface after I had been riding for 3+ hours. When I stopped for gas, the bike would not shut off with the ignition switch...it kept running as if nothing had happened. I was able to shut off the engine by using the R handlebar kill switch but the headlights remained on. I was able to turn off the lights by using the "added power kill toggle switch". When I reset the added toggle switch, the lights remained off. I had noticed that the radio stopped playing after about 2 hours of operation.

The radio seemed to be unresponsive to re-set and worked only 1 other time for a few hours on my 3 day return trip. In most cases (80%+), I had to use the combination kill switches to shut off the cycle for fueling or stopping after operations on 1+ hours. The ignition switch alone often failed to shut off the bike and lights...but not always... With short run periods, the bike would usually shut down "normally" by turning off the ignition switch. I did not experience any malfunction with the indicator lights in the dash or the guages, tach etc. for the entire trip back to WI.

Upon my return to WI (09/25/07), I tried to find and correct the cause for the electrical system problems I encountered. The horns were completely missing...I did find (per schematic) the cut power supply wire for horns just hanging loose and unattached. It was then that the observation was made that the ignition switch had been changed to a non-Kawasaki "generic" switch and that the added "power shut-off" toggle switch had been installed by a previous owner (reason unknown...previous owner unknown). The added switch was spliced into the batterry supply wire to fuse box (the original Kawasaki wire cut ). The wiring to the added switch was much undersized (#14 wire) and very poorly done. It showed eveidence of some melt-down of insulation and probable grounding at times to the cycle frame. I replaced that wire with appropriate sized and hoped that would solve all the electrical anomalies I had experienced.

It did not solve the problems. The radio would work unpredictably on and off...the intercom would transmit but was always on to voice transmission...radio was not audible in helmet speakers. There was further evidence of sound system modifications ... a added expossed in-line wire resistor ( I think aprox 1000,000 ohm) was "wedged" into the fuse box as was the power supply wire for the aftermarket running lights. I could find no such reference for this type of component in any of the service manuals that came with the bike (full set of shop manuals from Kawasaki).

3 weeks ago, I returned home from a brief ride, I turned off the ignition key...the bike stopped and lights remained on. I again used the "add-on power shut-off switch" to turn off the lighrts. I then tried to start the cycle again but there was no power through the ignition switch...nada...no indicator lights, and no starter. Repeated efforts to work the switch had no reffect. All the fuses were intact and power was indicated in the fuse box.

Upon close inspection of the fuse box, it did appear that there had been a previous power surge (prior to my ownership) thru the ignition fuse as the out side of the plastic fuse leg appeared to be partially melted. Testing showed that connection was still functional however. I talked with a Kaqwasaki dealer service tech and the suggestion was to replace the ignition switch first, and then if that did not solve the problems to replace the fuse block assembly also.

I have just replaced the ignition switch with a Kawasaki OEM part. The cycle will now start and shut off using the key but....NO HEADLIGHTS, NO BRAKE LIGHTS, NO DASH INSTRUMENT FUNCTION, NO WARNING LIGHTS(DASH) . The directional signal lights do work. I then replaced the fuse box assembly with a Kawasaki OEM unit but no difference...no change. I have checked all the fuses in the fuse box and all are good (I had checked these at each step along the way and no blown fuses were ever experienced).

I have cleaned all the electrical connectors on the front half of the cycle (used electrical contact cleaner on both male and female ends) looking for evidence of poor contact, oxidation, corrosion etc and found nothing unusual. I have removed the "added" in line resistor to fuse box and supply wire for the aftermarket running lights...but still no effect. I have tested the various relays and they function normally. Right now , this is the functioning condition(s):

The cycle will start in normal fashion using the ignition switch with the handle bar kill switch to "On". I have no headlights, no parking lights, no brake lights, no radio, no CB, no tach function, no gauge fuction (fuel, temp) no dash indicator lights ...I have not been able to test for cruise control function with out running the cycle on highway. I do have tail light and directional signal lights and L/R indication of directional lights on dash. All the fuses are good. When the cycle is running, I do NOT have power to supply side of "headlight" fuse nor power to "ignition" fuse.

Sadly, I am not very skilled at electrical trouble shooting/ problem diagnosis and I am at my wits end. I have very limited income so I am unable to pay for extended "dealer labor charges" ($70.00+/hr) to find and fix the problems. I do have the shop service manual(s), but I have no clue what to do next or where to look...or how to "fix the mess". I would most gratefully appreciate any help ...advice...guidance...instruction you all may offer.

Thank you very much,

Bob Michaels
Madison, WI
e-mail: bobberwi53704@yahoo.com

[StarGate]

I'm not familiar with your bike or it's wiring but I know at some point Kaw started using a relay in the lighting system that only allowed the lights to come on after the engine started and voltage from the charging system would trip the relay. If I understand it correctly, this was done to take load off the battery so the starter had full power. With that many electrical devices, they may be set up on a similar relay. Check your schematic to see if it has a relay like this. If it does, then I would be looking in that area as a possible bad relay.