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Thread: 95 King Quad - no electrical power Reply to Thread
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  Topic Review (Newest First)
08-25-2019 11:43 AM
08-25-2019 11:43 AM
08-24-2019 08:03 PM
MJohnston86 I hate to revive on a zombie thread but this post was spot on my situation.

I inherited a 96 KQ that was stagnant for a long while. Got it running, and about 15 minutes it; dead. No lights, so I figured a short.
Found this thread and it played out just like OP. I pulled the blown main 20a fuse. Went to replace it. Sparks. Instant blow. Pulled apart the ignition box, straightened out the wires and double checked all the connections. Popped in a new fuse. Cranked right up. Let it idle for about 10 minutes, and boom dead again. Wasn't even touching the bike.

I'm at a loss and I'd really hate to have to strip this thing down. Are any of you guys still around and maybe have any advice? Thanks in advance!
09-07-2012 02:13 PM
BlueQuad Yeh it was that connector - 6 or 8 pins inside it I think. It was bone dry in there. When my son first had the problem, I figured maybe something got water in it and was shorting out and maybe it would dry out and get better, but it didn't. Hard to say it was anything specific at this point, but it was obviously something between that connector and the starter button.
09-07-2012 11:44 AM
Tim Excellent! Was looking grim there for a bit. And yeah, it is nice to have a smoking gun.

Yellow connector in speedo housing right? I'm thinking maybe it got wet and shorted or had loosened just enough to arc across contacts. AJ would tell you to spray with contact cleaner and coat with dielectric grease.

Or maybe some of the contacts in switch housing shorted together.

Anyway I hope all stays well. Come back if not.
09-07-2012 11:16 AM
BlueQuad Tim, I didn't until you mentioned it. There was one screw in the back of the speedometer/switch housing that was being stubborn but I finally got it out. I traced the start switch cable from the connector, down the wire that was stuffed down into the front of the bike at the neck and then disassembled the start switch housing. The connector in the speedo housing seemed to be firm but I disconnected it, put a new fuse in and it didn't blow. I examined the wire bundle closely all the way from the connector to the start switch and didn't see any kinked or scraped or cut wires. The wire bundle wrap was also completely intact with no holes or cuts in it. So, with the wires still pulled out as far as I could get them, I plugged the start switch connector back in and turned on the key. The fuse did not blow. I was able to start the bike right up and it ran fine. I put everything back together and it still started and ran fine. With the bike idling, I wiggled and jiggled every wire I could find and cut the handlebars full lock left and then right, still no problem. Took it for a test ride and it's still running fine.

All I can imagine is that there was a connection that had worked its way loose somehow or a wire was getting pinched at a weak point. I wish I had found a solid reason for the problem so I could feel better about the fix. But the bottom line is the bike is running again and my son will be very excited when he gets home from school. Just in time for the weekend after a long week of school, soccer practice and games.

Thanks for the support and suggestions here.
09-07-2012 08:31 AM
Tim Did you open the handle bar switch housing?
09-07-2012 08:26 AM
BlueQuad I'll take one more stab here to see if this might be a clue to anything. I've tried to check every connection I can get to (which isn't many), including the recently reconnected starter cables and I don't see anything that has come loose or gotten cut or broken.

Anyway, I just went out and put a new 20a fuse in the main. I turned the key on and the dash lights lit up as normal. I thought something had changed because before the lights would come on for a second, the fuse would blow, and everything would go dead again. This time everything stayed on. Until I hit the start button. The starter turned over and didn't crank (not unusual on the first try), but then the fuse blew again. I put another new fuse in it, and when I turned the key on it blew immediately again, just like before. Would this point to anything specific?

If not, I guess it'll sit and rot or go to someone that knows more about what to do.
09-04-2012 07:47 PM
Tim Yeah should be 2 screws in the housing. Might be some other little bits to take apart in there too.
09-04-2012 06:11 PM
BlueQuad Thanks. I dont have the front taken apart yet. I like to have some idea of what i am trying to accomplish and how before digging in and making things worse. I would like to check the ignition switch first. How do i get to it, just take the screw out of the housing?

As for the fuses, i realize i will have to use them for troubleshooting. I only meant i didnt want to just keep throwing fuses at it without looking further.
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