Z1OwnersClub GB

Just ready to put new pipes on a Z1A after complete ground-up overhaul.
I thought I would shortcut the completion of this project by asking the forums for suggestions/ diagnosis of electrical problems.

Starter Solenoid
The starter works when I put a screw-driver across the two 6mm terminals.
Rear tail & brake lights
Checked bulb both filaments OK!
Rear tail light not working.
Rear brake light working!
Idiot lights
Neutral light not working. (bulb not checked)
Pressure light not working. (bulb not checked)
H'beam light working.
Blinker light working.
Instrument lights working
Brake outage light in tacho working!
Front brake
... awaiting bleed

I suspect a fault at control panel.
Wiring at control panel has been renewed, new main harness, new alternator harness and new gel battery.
Could possibly be in head-light or idiot light bulbs.
Solenoid could have faulty primary winding. Oh! Horn and headlights are working!
Suggestions welcome.

RegardZ

have you fitted a combined regulator/rectifier? & connected the wrong block connector into the vacant regulator connector on the main panel. it seems like you have no switched live/ brown wire. check the brown wire from the ignition switch + trace it back to your handlebar controls

Hi Garn suspect bad earths, though other comment valid not had frame powder coated by any chance?excellent insulator that stuff!!! specially through handlebar clamps etc!!!! Paul J

Garn don't do powder coating, if he does won't talk to him anymore!

Agree with others, bad earth.

I always run an extra earth wire from casing earth (near kick starter) up to the wiring harness mount bolt (under plate near bottom rear fuel tank mount), if still have trouble, run a temp wire from bolt under plate as mentioned to a handle bar bolt, might show up if bad earth in goose neck/kill switch area.

Thanks for the replies.... I will have more to say later about these electrical problems.

Fistly, I checked out Z1Bman's theory on connecting wrong block (green or white) at main control panel when using combined reg/rectifier.
I am using a combined unit and I found with lot of unwiring that these terminal blocks (green and the white) are exactly the same configuration and that either can be used as a connector plug for the combined unit.
However, this exercise lead me to find the main problem (More about that tomorrow).

I was terribly puzzled by power to the brown wire, mainly because I had power to the horn, the blinkers and the foot rear brake (front brake light not checked) all of which, rely on the brown wire.

The solenoid problem was as predicted ... stuffed primary winding.
You should always hear a "click" as the solenoid rams the slug to the main starter contacts, when you connect the primary side (black and earth) wires to 12 volt supply.
Solenoid was replaced ******.

Bad under seat connection to rear tail-light ..... Fixed*******

More tomorrow. You will never guess the mistake I made!
Clue.... Although investigated the problem had nothing to do with the beautiful powder-coating job on this Z1A or it's earthing.

RegardZ

Well, I have some photo's of my findings (having a lot of trouble loading them with Photo Bucket)
Anyway, prompted by Z1bman to look at the control panel terminal blocks, I found I had some of the blocks turned 180 degrees.
I always thought they could only be plugged in one way, evidently not!.
I had replaced these blocks in the control panel, as part of a new harness component. They are marked to show their position on the plastic, however, when assembled into the panel the female section markings cannot been seen.
If had looked closely enough, I would have noticed the metal part of the terminal block is shaped like a "D" and they all should have been the same direction. Every thing worked well!

I only have one small problem now... the neutral switch is still not working, I'll have a look at that when I take the sprocket cover off. It may be the bulb.

Thanks again guys.
RegardZ.

There you go GarnZ1A, I'II email the instruction to you soon.

Pic only showed up small, problem your end Garn, when you loaded your pic to Photofucket.

Thanks RGH, I think members will nut it out from there.
I spent over an hour on trying to download those pictures.
Just read Jay1969's post in Discussions and realised I could not copy the IMg code..... Loaded Flash updates and installed in my iMac and it seems to now copy....

Hopefully you can view that above picture.
The top bank of contacts blocks is correct.
The bottom bank has the brown, white & green plugs installed 180 degrees out (notice the metal section) my error
RegardZ.