Tail Light Troubles '84 ZN700 LTD

[yinseriv]

Just bought an '84 ZN700. It only has 4635 miles on it, original equipment and runs good. The problem I am having is twofold. I have to turn the key in the ignition and find a 'sweet spot' which is at about a halfway setting to turn her over. Then I have leave the key in that position. However to engage my tail light the key needs to be turned far right. When I do this the bike shuts down.

So here is my question. Do I have an ignition switch wiring problem or do I not know how to correctly start this bike? I live in the Northwest and really need a tail light in the year round rain and fog.

[antiq]

I'd look over the wiring to see if a PO has cut or spliced anywhere. If you find any check to see if any connections are loose. If the wiring looks right then I'd check the switch. See if it is functioning as the wiring diagram says it should. My 82 750 works just fine on the first setting. I haven't even tried to turn it to the second position. Might try that later just to see what it does.

[StarGate]

I had a very similar problem having to set the key in a midway position and discovered the bottom of my ign switch was comming off and allowing the contancts inside to not connect properly. I had to take it all apart and clean the contacts and put it all back together. It was a pain to get it all back together but I finally managed to do it. There were 3 sets of contacts inside with one set for lights and another for power to the starter and coils so you might want to look at that too.

[wiredgeorge]

The problem is the ignition switch. You can disassemble most of the older switches and clean the contacts. If you do, be careful as there are spring loaded detent balls inside that will want to get lost. The reason for cleaning the contacts and going to this trouble is that the key also fits the steering head lock, helmet lock, seat lock, etc but if you use an aftermarket ignition switch, you will need to carry two keys. It is basically a decision on whether you are more comfortable disassembling and cleaning an old switch or carrying two bike keys.

[yinseriv]

wiredgeorge;

Awesome man. Thank you. I'll be cleaning and rebuilding the switch.

[yinseriv]

StarGate;

search & rescue saves the day again. Thanks for the input. Clean looking bike you have there. Hope the popcycle days are still shining down your way

[yinseriv]

Thanks antiq. I will for sure be redoing some wire. The sea salt up here has a way of getting where it shouldn't go.

[antiq]

While you are working through the wiring and switches. You can prolong the life of your repairs and electrical system by investing in some dielectric grease. Put it every connection ,contact and bare wire you find. With sea spray and fog prevalent in your area you'll need all the help you can get to keep the the electrics from making their own circuits. Old wiring connectors are usually not well sealed. You may also want to get a good seal for your points cover. Just some thoughts.

[yinseriv]

Good tip. I did already repair a nest of splice from PO. I always get concerned when I see a ball of electrical tape used as insulation. Plus thanks to all. I rebuilt the ignition switch like suggested and the lights work fine.

[OKC_Kent]

I thought the ignition switch works that way on purpose??

My '78 may be different than a newer '84, but it has 3 positions. Far left is off, middle is for running, and far right just turns on the tail light. I'm sure it clicked into position when new, but being old it doesn't click as firm as it once did.

[antiq]

Glad to hear you're back in business.

[Chevy]

Definitely a bad contact in the switch. Clean it and you should be in business. You won't have to carry two keys or pay alot of money for a new switch. Win-win in my book.

Your ignition switch should have four positions to it. Far left is off with the steering head locked. Second to the left is power off with the steering head loose. The next position (second from the right) is the on position. This will power the horn, the ignition, both taillight circuits and the hazard switch. The final position to the far right is the park position with the steering head locked but certain circuits powered. The horn, the ignition and the brake light circuit are unpowered while the dimmer taillight bulb and hazard switch remain powered. Both the far left and the far right positions require you to push in the key to select them. (But I'm sure you know that bit already.)

All this info comes from a combination of my 1982 Spectre owner's manual and the 82-84 KZ750/ZN700/ZN750 repair manual. If you need a wiring diagram, let me know. I don't haunt this place like I used to but I check in every so often.

[ZappBranigan]

Interesting thread. My previous Kawi was an 84 ZN700 and it had problems with the ignition just intermittently shutting off for no reason. This happened frequently in 2003 when I rode to Sturgis. It was frustrating. In 2005 I sold the bike to my brother, who still has it. He does occasionally get the shutting off problem but it's less frequent. He's had the bike gone through so he's sure it's the ignition switch as well. Apparently a weak point on this model? I hope my 82 Spectre isn't subject to this kind of thing, but at least it's easier to get parts for than the ZN. I noticed with dismay that the ZN doesn't show up on Bike Bandit's parts list for either 84 or 85.