650 Wiring Issue

[echolsd]

Wiring gurus I need some help! I'm recently bought a 650 that would crank but does not run. Pretty much all the electrical parts have been replaced and the wire colors not matching up have me confused. How should I connect the following:

Stator:
Brown
Brown
Yellow/Black
Purple

Voltage Regulator:
Brown
Brown
Black
Red
Red

Coil:
Red
Black
Black
Black/Blue

Starter Relay:
Orange
Orange
White
Black

Starter Switch:
White
Orange
Blue
Black

Everything has been replaced except the starter relay and start stop switch. It would turn over but not fire even pouring fuel in carb and in cylinders. Obviously, the parts are not OEM or else the colors would match and be simple. Any help would be greatly appreciated.

Thanks in advance for your help.

 

[WFO Speedracer]

I say this pretty much every time but you are wasting your time with those cheap knocloff parts if you goal is to ride, now if your goal is to wrench on stuff constantly you are on the right track.

 

[echolsd]

I appreciate your opinion and have been burned by aftermarket parts in the past; however, this is what I have to work with currently and was just looking for some help.

 

[WFO Speedracer]

First off 650 what exactly , year and model ?


Secondly without knowing the colors on the harness for the switches no one can help you, it's just guesswork.

Third ask better questions and you will get better answers

 

[echolsd]

Sorry Speedracer. I’m new in the jetski markets. I didn’t realize Yamaha had a Super Jet as well so thinking I was in the Super Jet thread y’all would know it was a Kawasaki. Mine is an 1984 Kawasaki 650sx. The guy tried replacing most everything before I got it from him. That’s what I meant by what I have to work with. I was hoping to figure out which wires went where from you guys that have been doing this for a while without buying all new stuff. The wiring details listed are the various harnesses from each of those pieces. Let me know what else I can share that might help. Thanks again.

 

[WFO Speedracer]

Well lets start with the stator and voltage regulator , obviously the two brown leads from the stator hook to the two brown leads from the regulator, the red lead on the voltage regulator hooks to the orange lead coming off of the battery post on the starter solenoid , the black lead off the regulator hooks to ground.

Your other two stator leads are black- yellow which hooks to a ground (or black) and the purple lead will hook to the red wire on the coil -CDI , the black wires on the coil hook to ground and to the black wire on the stop switch , the black- blue hooks to the blue wire of the stop switch .

Starter solenoid wires white hooks to white , orange hooks to orange.

Basically Orange is system power , black is system ground . white energizes the starter solenoid , blue shuts down the spark by sending it to ground, there is probably also a stopper switch in between the stop switch and the CDI, it will work without it but you have to hold the stop switch down till the engine stops spinning.

Your two brown wires are for the charging coil that charges the battery which is why the red lead off the regulator has to go back to the battery through the orange wire, the purple wire is for the source coil that powers up the coil -CDI.

 

[OCD Solutions]

Here's the Yamaha wiring diagram for reference. All colors should match up exactly if you are using OEM parts.

 

[WFO Speedracer]

Here's the Yamaha wiring diagram for reference. All colors should match up exactly if you are using OEM parts.

650sx and from what he said all non OEM parts.

 

[echolsd]

Hey OCD. Speedracer is correct but they may all be OEM before it’s over. I wired it according to the plan but no spark at the plugs. This is the fun wrenching you talked about earlier.

 

[WFO Speedracer]

Yep now you are going to have to start doing some checks with a volt-ohm meter and find out why.

I would start by disconnecting the purple wire and checking AC voltage while cranking, you are looking for around 35VAC or more.

 

[echolsd]

Only showed 13

 

[WFO Speedracer]

Well there there you go

 

[OCD Solutions]

I just saw the title and what section it was in and jumped in without reading further. You got the right man's attention if it's a 650SX though.

 

[echolsd]

Looks like non OEM strikes again! He sent the old one he swapped out. Any way to test it off the ski.

 

[WFO Speedracer]

Looks like non OEM strikes again! He sent the old one he swapped out. Any way to test it off the ski.

You can check resistance of the coils but that's all off the ski.

Set your meter to x 100 ohms scale and you should have between 255-380 ohms resistance on the exciter coil.

 

[WFO Speedracer]

I checked one off a ski that the guy smoked the ground wire on and I got 317 ohms well within specs , I am repairing the wiring and keeping it as a spare.

 

[echolsd]

Sorry. Life happened and I haven’t been on for a while. It tested bad as well so I ordered a new one. I’ll let you know how it goes. Thanks for everything!