Battery Cables

[samchar12]

Looks like I need to replace the battery cables on my ZN1300. I see they aren't available anymore and wanted to know what you out there have found. What about the start solenoid as well?

[jorgeno]

If the solenoid is ok, keep it.
Have never replaced the battery cables, but think it’s straight forward. Good clean connections, and you are good to go :-)

[samchar12]

When I go to start it it will crank a little then the cables and solenoid get very hot and all it does is click. Leads me to believe there is too much resistance in the cables and/or the solenoid is failing. The battery is brand new and in good charge so don't go there.

[cranky]

... heat = resistance, be sure the connections are clean and add dielectric grease to
keep corrosion out.... Best to Ya!!!!

[samchar12]

Everything is clean, which is why I am asking where you all have found cables and a solenoid as they are no longer available from Kawasaki.

[cranky]

IIRC, the parts supplier of choice is the internet: Ron Ayers,
Partszilla, and my fav, Ebay.... we have old machines and
used parts are an option... Best to Ya

If you have clean connections and the wires are gettin hot,
I'm very surprised you are not blowing fuses!!!! You must
be drawing a gazillion amps!!!

[Thadbaker86voyager]

I would be questioning the starter.

[samchar12]

What makes you say that? Can I test it? I know without the plugs in it spins great, but with them in I get a lot of clicking and the hot wires.

[Thadbaker86voyager]

I am thinking starter from past experiences with car/truck/tractor starters. No experience with your exact starter, just a hunch.

[samchar12]

Would I be better finding another one or rebuild the one I have?

[Thadbaker86voyager]

If you had a known, good starter, that would rule the starter out good or bad. I bet there are specifications on testing it. I know the 1200 service manual gives processe for testing it. Not sure if that would help any on the 1300.

[jorgeno]

Any progress? If it’s the starter motor just replace the carbon brushes. Easy and much cheaper. See page 243 in the manual for troubleshooting the electrical starter system

[samchar12]

Haven't had time to look at it. Will see if I can get the starter out this weekend and open it up.

[samchar12]

Pulled the starter and opened it up. Smells like burnt cheap cigars. The inside also has this weird brown goo stuck all over it particularly the plate the brushes mount to.

Will find another starter and give it a shot. Not sure this one is worth fixing.

[samchar12]

One other thing is the wires for the brushes do not have any insulation on them. One has some left, but the other 3 wires are bare. That might explain the burning and heat issues if the starter is short circuiting itself. Can you buy just the brushes? I haven't found anyplace that has them.

Thoughts?

[jorgeno]

You can order it here:
https://www.cmsnl.com/kawasaki-zn1300a4 ... 4RMRaQ8yaM

Part number 21039

[samchar12]

Put in another starter and it cranks great. Still won't start, but I have a feeling its the coils. 1 problem down, several to go. May be time to just sell the thing and buy something reliable.