Kawasaki Brute Force 750 ATV Bus Connector Problems; A Random Tech Tip

This is a unique problem that affects 2005 & 2006 Kawasaki Brute Force ATVs, you would think that by now all of these would have been fixed already but every now and then one still shows up. Anytime you have any electrical problem with one of these four wheelers this is the first thing you should check. Battery not charging, 4wd switch not working, lights flashing, or any other electrical fault of any kind you should remove the rear fender unit and check the wiring harness for a rectangular bulge like this. <2006 Kawasaki brute force bus connector> There are two of them one at the rear over the gas tank & and one almost in the middle. Usually it is the one in the rear that causes the most problems. This is the front one in this picture. <kawasaki brute force front bus connector> The next picture is of the rear connector, notice that it is packed with mud despite the fact that it was sealed up inside of a tightly wrapped electrical harness. This causes either broken connections or direct shorts depending on how your luck is at the time. A couple of the wires just fell out of this one. <brute force atv rear buss connector> Although I have heard of these connectors failing on machines that were not abused, in all honesty if you just keep your late model atv & it’s computer controlled engine out of any water deeper than the top of the differentials you are unlikely to have any problems. I am not going to give you a step by step tutorial on this repair, but will give you links to a couple of excellent ones that already exist on the great tool know as the internet. The first one is at the Mud In My Blood forum and you can get to it by clicking here. One thing that is incorrect in this one is that the author thought that the factory had fixed it starting in ’06. I can assure you they did not as the pictures above came from an ’06 model that I fixed yesterday. Another great one is found at youtube if you would prefer to watch a video, just click on this link right here. What ever you do be sure that you seal your final connections up tightly before re-wrapping the wiring harness and taping it back up. Go play in the mud again just remember it costs cubic dollars in repairs to keep using your land vehicle as a boat or a submarine! Unless you get an Argo 😉

If you liked this post or found it helpful.
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Gords Garage Blog The February 2014 Website Of The Month

Gords Garage Blog has one of the best subtitles I have ever read, “I am not a professional and I try things at home.” The is probably one of the most mechanically inspirational blogs I follow. If you are into metal working and motorcycles you need to go check this guy out. At the time of this writing he is just putting the finishing touches on a fantastic looking CB160 cafe racer. Gord has a well equipped home shop including machine tools and welding equipment along with a lot of talent & imagination so you are sure to find some good ideas for your next project if you look. Click here to visit Gord’s Garage.

 

 

 

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1985 Kawasaki 454 LTD Another Junkyard Dog.

This one had been leaning up behind the fence in some guy’s back yard for a while…

<1985 Kawasaki 454LTD>

<1985 Kawasaki 454LTD>

the droopy turnsignals are kind of sad looking

<1985 Kawasaki 454LTD>

 

Back in 1985 Cycle Guide raced on of these against a 454 Corvette and spanked it good. But time has not treated this little Kawasaki well.

<1985 Kawasaki 454LTD>

<1985 Kawasaki 454 LTD>

<1985 Kawasaki 454LTD>

Somebodies kids tried to fill the tank up with dirt.

Notice the relatively low miles on the odometer, like so many motorcycles this was ridden for a while until the owner got bored with it or scared of it and it was left to rot. It no doubt switched hands a few times and had the same sequence of events happen over and over until finally something broke or the carbs finally gummed up and no one cared to fix it.

<1985 Kawasaki LTD 454>

<1985 Kawasaki LTD 454>

<1985 Kawasaki LTD 454>

 

 

 

 

 

 

 

 

<1985 Kawasaki LTD 454>

 

This side view below shows that these bikes had a fairly good looking profile but even then the writing was on the wall for the fast, good handling, and comfortable 2 and 4 cylinder Japanese cruisers. Lighter & faster was no longer fashionable, so the big four answered the demands of their American customers, who really wanted a 1960s-70s Harley but with Japanese reliability & no oil leaks. It’s a pity because I think it would’ve been interesting to see where these designs went if they had continued to combine cruiser styling with super bike technology.

<1985 Kawasaki LTD 454>

Here’s a little bonus picture, not really big enough be a dog, we’ll call this one a junkyard puppy. It got thrown in on the deal with the Kawasaki 454 LTD above. It’s a little Baja MB165 mini-bike. A friend of mine has one & I really enjoyed riding it, and wanted one of my own, but never could quite convince my self to buy one. This one was left to rot after mommy & daddy got tired of replacing clutches on it. Most people don’t realize when they buy these mini-bikes (or go-karts either) that the clutches are expensive consumables that have to be replaced on a regular basis. I going to put a torque converter on it, a bigger rear sprocket & some ATV luggage racks to make it into a modern version of the old Tote Gote.

<baja mb165>

A Good Day’s Update

<project wAMMO Honda CM400E>

All went well today! Did I do everything I hoped to? Not really but I always tend to be overly ambitious anyway. Got that crazy four wheeler cranked up, now I need to fix the charging system on it.

<measure it at least twice>

measure it at least twice

<and cut once>

and cut once

 

Got the rear fender and the lighting mounts figured out for this old Honda. One of the things I learned in art class is that you sometimes need to step back away from the canvas so you can see what need to be changed or done next. With that in mind I backed this off of the table and rolled it outside in the rain for a few pictures. I think the basic shape is coming together and will be okay with a custom built seat to bridge the gap between the tank & the rear fender.

<roached out Honda Chopper>

Going to get that steak & beer now.

Peace Y’all

It’s Going To Be A Great Day!

What in the world am I doing out of bed at 5:30 am on a Saturday morning? Hunting season is over and I don’t have anywhere to travel to, so why am I up, sitting at this computer, drinking coffee and writing to you? The reason that I am so excited is that today I get to go out to my shop and work on motorcycles! I have been incredibly busy doing such things as replacing the steering column in my old Chevy van, doing a bit of work at my place of worship, and setting up my web store that is attached to this blog. But today things are different and I plan to take full advantage of it.

There’s a new AGM battery hooked up the trickle charger in the shed, it and a couple of gallons of premium gas are going into a Kawasaki Brute Force 750 that I rebuilt the carbs on a few weeks ago. The new rear fender came in for Project wAMMO and I have the exhaust pipes welded up and ready for a trial fit. My main goal for today is to fit this rear fender and get it mounted into place. The owner didn’t really like the Fat Bob fender so I bought a new Electra Glide style front fender that will be turned around backwards and cut down to fit. I can already see it in my mind, and it looks good.

Somewhere along the way I picked up a seriously roached out 85 Kawasaki LTD454 that you’ll see in the Junkyard Dogs section of the blog soon. If I can talk my wife into it I’m going to teach her how to rebuild carburetors using it for a project. The guy I bought it from poured some gas into the carbs and it started up and sounded okay, but it really does look awful. If it runs really good, it might become a project, or even if it runs okay, it still might go to the VMA swap meet as a box of parts.

A while back Cycle World editor Kevin Cameron wrote a great piece titled “The Tyranny of Tools,” and he was so right sometimes having the knowledge and equipment can be a pain. You really wish you didn’t have the ability to do things, such as replacing the steering column in a van or repairing your homes heat pump, but even if your significant other can be convinced to let you sub a job out, the demons in your mind will insist that you do it yourself just to make sure it is done right. But on a day like today I am the tyrant and the tools become my army and we will conquer the tasks at hand. At the end of the day when the recalcitrant metal has been subdued and the projects are that much closer to completion, or in fact done, we will celebrate with a nice medium rare slice of dead cow served with a bottle of that Irish brewed nectar of the gods, Guinness Extra Stout.

Gee I hope I am still as happy at 6:00 pm as I am at 6:00 am….

 

How to Get Better Fuel Mileage Part 1

A couple of weeks ago I promised to do an article about motorcycles and fuel economy, since it does seem to be popular subject people are searching for more information about. There are many things to consider, but perhaps the biggest single key to getting the most fuel economy is to start with the right motorcycle. For the sake of this article we are not going to be considering anything not capable of running at least 60 mph thereby completely eliminating all of the “moped” class machines. Although if you live in a city and do a lot of driving in areas with low speed limits you may still wish to consider one.

This is by no means meant to be a complete listing. Your mileage may vary etc. There may be many similar or equal machines to the ones that I have named below so don’t beat me up if I left out your favorite. Please note figures given are gleaned from EPA ratings, personal experience, and/or reliable motorcycle data websites, and apply only to well maintained factory stock machines.

<Sym Wolf Classic 85 mpg>

Sym Wolf Classic 85 mpg

The smallest machine that I looked at for this article was the Sym Wolf 150, a great looking little machine. Light & nimble it is the smallest motorcycle I would consider for street duty, other than the CB125 that the Wolf is a direct descendant of. Rated at 85 mpg it has great fuel economy, but has a top speed of around 65 mph, and being a very small light machine without much load capacity, I’d recommend you stay off the freeway with this one.

<Royal Enfield Classic 500 85mpg>

Royal Enfield Classic 500 85mpg

Surprisingly enough the next motorcycle up in the mpg sweepstakes is a heavy solid steel piece of spiritually British iron. Built in India for several decades, the Royal Enfield 500 has gradually evolved from a clunky unreliable relic, into a machine with a reasonably modern fuel injected engine slotted into a chassis that is still a relic, but in a good way. 27 hp combined with heavy construction isn’t going to win any drag races but the 85 mpg is astounding in a machine with enough torque for passenger hauling, and with an 80+ mph top speed you can still get on the freeway and go places. I probably wouldn’t keep it pegged WFO for hours on end but it is still capable of interstate travel at a relaxed pace.

<CCW Tha Heist 80mpg>

CCW Tha Heist 80mpg

Next in the range are the 250 class retro & cruiser bikes such as the CCW’s Tha Misfit & Tha Heist, the evergreen Honda Rebel and Suzuki TU250 fit this group as well. These are decent little machines that are capable of up to 80 mpg. Extensive Freeway duty is a bit questionable on any of them but they are definitely a step up from the smaller Wolf. If you gotta travel the high speed roads you should probably look at the Japanese offerings first. The CCW bikes are great looking though and they do have a catalog of hop up parts to get more speed out of them but that will probably diminish fuel mileage.

A small step down in fuel economy but a huge step up in performance is the 250-300cc sport bikes such as the Kawasaki Ninja & Honda CBR. The baby Ninja can get just a tiny bit past the ton in bone stock condition even with a fat boy like me on it, and while I haven’t ridden the CBR250 yet, all the magazine testers put its top speed around 97 mph. The best part is that both of these bikes are as reliable as anvils, more than capable of traveling anywhere you want to go at any legal speed without ever breaking a sweat. Being fast enough to beat most cars at the stoplight drag races is also a very comforting safety feature as well. These bikes are capable of 70 mpg when ridden conservatively and still knock down over 55 mpg when you ride the snot out of them.

<Honda  NC700X 64mpg>

Honda NC700X 64mpg

I have consciously tried to avoid singling out any one machine for praise, especially one that I have not ridden yet, but the Honda NC 700 X is rated at a very good 64 mpg. This is a full size 700cc adventure touring type machine capable of cross country touring on any road of your choice. Compare that to a big scooter such as Honda’s own Forza with its streamlined bodywork and 300cc engine that only gets about 4 mpg more.

There is a huge range of motorcycles that slot into the 45-55 mpg range. Harley Sportsters, FXRs, etc., most cruisers, vintage bikes in the 350-850cc range. Practically every 600cc sportbike made by anyone can get 50 mpg+ and provide amazing performance. Even some of the 900-1000cc bikes can do 45 mpg. At this range the cars are starting to catch up mpg wise but these are incredibly slow & boring cars that get this kind of fuel mileage.

<kawasaki-ninja-zzr1400zx14>

It only gets 33-39 mpg but does anyone really care?

You don’t really drop below 45 mpg until you get into either hyper sport machines such as the ZX14 Ninja or the Hayabusa, or full dress touring motorcycles like the Gold Wings, K1600 BMW, & Electra-Glides. Even so most of these machines are still capable of 35-45 mpg averages. While they are not economical sounding in motorcycle terms, in the economy of scale against other forms of transport with the same intended mission they are still very reasonable. The big touring machines are incredibly luxurious and loaded down with more amenities today than anyone ever thought possible. To get a performance automobile capable of matching the speed of a box stock big bore sport bike will cost you at least $100,000 and it won’t get anywhere near 30 mpg.

<Electra Glide Ultra 42mpg>

Yes the biggest Harley is rated at 42 mpg combined. Impressive.

As I said at the beginning if fuel mileage is what you are after in a motorcycle, the best way to get it is simply to buy the right motorcycle, maintain it well and ride it in a careful and conservative manner, keeping your speed down as much as safely possible. I’ll come back in a few weeks and touch on some maintenance items that you need to be sure to keep up with to maximize fuel economy, and at a later date will write a post about modifications & driving techniques, to help you wring every last mile out of your dollar.

The Old Biker Speaks. A Parable for the Modern Motorcycle Lover

Warning; When I wasn’t looking someone slipped a couple of naughty words into this one. No f-bombs, gratuitous sex, or boob pictures though, sorry.

 

Imagine that you are gathered with a group of your fellow motorcyclists, be you a group of yuppie cruisers, hipsters on retro style bobbers &café racers, hardcore chopperheads, or restoration junkies. Everyone is standing around, taking a breather, checking out each other’s bikes, telling interesting half-truths & just generally having a great time in the way that only a bunch of bikers can. The sun is bright; the beer is cold, and the ladies beautiful. It is truly a perfect day as long as no asshole decides to ruin it for you.

Somehow there is just one brief moment of silence and I heard it, far away in the distance the howl of an ancient four banger breathing out through a quartet of totally baffle free drag pipes. The exhaust note is raspy & uneven, and you catch the whirring sound of a loose cam chain, all obvious signs of deferred maintenance that would kill a lesser engine, but as we all know, some of these old SOHC 750’s will never die no matter how ratty they get.

By now the whole encampment has heard the sound and is looking up the winding road coming down the mountain to see what matter of machine is headed towards them. Some are commenting about how rough it sounds, others somehow seem to be watching in fear as if it may be some kind of hipster/yuppie/brand loyal purist eating dragon coming to consume them.

<old school Hipster eating Chopper>

It finally flashes into sight coming around the curve, a creature from another time, impossibly long, the rear wheel bouncing up & down in an ancient Amen Savior plunger frame. The front tire too bounces up, down, left and right as the rusty peeling girder front end rattles and shakes with each imperfection in the road surface. The bushings in the girder are shot & so are the steering head bearings. There is no way this thing should be moving so fast, especially on this twisty road, but it is.

As it approaches our group the rider lets off the throttle and downshifts, causing the engine to backfire on the overrun, blam! blam! blam! as flames pop out the ends of the exhaust pipes, that appear to have been fabricated from metal conduit 40 years ago. Small animals & nervous people immediately begin plotting escape routes, after all sensible people are afraid of folks who ride deathtraps like this.

The paint job was obviously gorgeous a long time ago, in a galaxy far, far, away but has now suffered several decades of weather beating and a million miles of hard riding. Every top surface was chalky, and crazed with cracks, looking as though hundreds of overlapping cobwebs had been deposited on the tops of the frame, tank, & rear fender.

On the sides you could still see the remains of a gold base coat topped with green & red kandy paints, sprayed through chicken wire to simulate scales. Back in the day a pretty good 70’s air brush artist had written the letters FYYFF on the sides of the tank in black and purple colors, tee shirt lettering style. Modern day neo rat riders immediately snapped pictures in hope of finding a way to re-create this patina on their next project. The engine side covers had been chromed at some point but had become sand blasted & peeling, as were the rims. Most of the spokes, bolt heads, & all four exhaust pipes where coated with rust. A fantastically ornate king and queen seat that is a work of art in its own right, despite being threadbare & worn reclined against a 3 foot high trident shaped sissy bar with 3 rusty spear points aimed at the sky.

Rattling to a complete stop and switching off the engine and the fuel tap, the grizzled old rider swung out the side stand and leaned the bike over to park it. Looking on as open mouthed & slack jawed as the rest of the crowd I couldn’t help but notice a tiny golden trickle of gasoline dribble down to the edge of the oxidized velocity stack on the number one carburetor forming just enough of a droplet to catch the sun’s rays like a tiny jewel in a rusty can, but not a big enough dribble to actually leak out onto the ground.

The rider himself, was a fascinating creature, he rode helmetless without gloves, with just a leather club vest covering his torso. Of course this caused a great murmur of disapproval amongst the safety nazis in the group. Although when astride his magnificent steed he seemed much larger than life, standing on the ground before me he was just man of just below average size. Bald on top with 2 foot of long grey hair on the sides, he sported the pointiest goatee I had ever seen and a finely waxed handlebar mustache. His bald spot was covered with a tattoo of a spider web, & a POW-MIA flag graced his right shoulder.  Despite his diminutive physical stature, he gives out the overwhelming sense of confidence that only a man on a mission that knows he’s doing the right thing can posses.

Next our mysterious stranger unstraps a wooden box from the sissy bar of his motorcycle, throws it on the ground in front of us, steps up on it, and in the most corn fed southern accent you ever heard in your life says, “Hey y’all we need to talk about some of the crazy shit going down in the motorcycle business sometimes.”

I’m sure that most of you younger folk have heard of this newfangled thing called the internet and that giant worldwide marketplace called ebay. It seems that a man can find almost anything he might need to survive, motorcycle parts, vinyl records, silver, gold, knives, heavy metal posters etc. In fact about the only necessities you can’t get there are guns and ammunition because the owners are a bunch of politically correct pussies that don’t see the necessity of such things like we do, but I digress let me get back on track here. Lately I’ve noticed an alarming tendency of people to put things up for sale at what is called a “no reserve auction.” But when the item sells for less than they expected they just don’t ship it, or if the item doesn’t get up to a certain price by the last day they cancel it. I’ve actually had both of these things happen to me lately and it left a very bad taste in my mouth. I was actually planning to bid on one original vintage European motorcycle but passed it by for a different motorcycle only to have the shop that was selling it cancel the auction in the last 5 hours. If I’d known the sum-bitches was lying about the no reserve auction I would be the proud owner of a 75 Jawa right now. Instead I got a pocket full of pissed off & another shop on my list of places not to buy anything from.

Now all of you know more about the workings of the internet than I do, but apparently not everyone understands how an auction works. First off if you have a certain dollar amount that you have to have for something, you should never ever use a low starting bid, no reserve auction to sell it, never. Either you pay the fee for a reserve auction or set your starting bid at your bottom dollar price & let it go up from there. If you do screw up, use a no reserve auction and sell something for far less than you thought, man up, take the beating, & learn from your mistake. I’ve done it a time or two before I learn’t better. Also all dealers selling bikes should disclose all fees & taxes up front in the auction listing. The same goes for dealers craigslist ads too.

Now let’s speak about selling motorcycles without titles. Decent honest people know that in most places you can’t register a bike without a title. Now if you live in a place where you can register an old bike without a title I am genuinely happy for you, but in all honesty the only way you can get any money for it will be to sell it locally. Even if I lived in one of these states, for any bike that was less than 25 years old and/or worth more than 3 or 4 thousand bucks you should still insist on enough paperwork to ensure that the current owner is the legal owner.

In the rest of the states stop trying to get full price for them, without the proper legal paperwork they are either just a pile of parts, or if dilapidated or unwanted enough just plain old scrap metal, and should be priced accordingly. People constantly say, “You can get a title.” Well that is an expensive maybe at best. In my home state of South Carolina there is a process you can go through for vehicles over 25 years old. You fill out forms, send in pictures & money including sales tax for the purchase price, then you take it to the DMV office where they inspect it to be sure the serial number matches what is on your paperwork. They then run it through the database and if there is no current title for it in existence & it has not been reported stolen, they will issue you a title. If the vehicle is not running at the time you will be given an off road use only title no matter what kind of bike it is. So once you get it restored you have to trailer it back to the DMV for a second inspection, and pay a second title fee to get the off road brand removed. When you count the time off from work this can run several hundred dollars. So to me, even a good running fair looking bike without a title is only worth ¼ to ½ as much as the same bike with a title. It’s gotta be cheap enough that I can take the chance. A rusty, locked up, old rice grinder that has no visible good parts on it or is of no collectible value should be weighed and sold by the pound at your local scrap yard. A number of you don’t even have the options that I have here in S.C. As for the title service companies there are many reputable ones out there, but even so you are still looking at hundreds of dollars in some cases to get paperwork. The last quote I got from one was ten or twelve years ago and it was nearly $300 then, and I am sure the price has not gone down any. Some states may have laws against using out of state title services so be careful and find out if yours is one of them.

The most dangerous thing I have ever seen in an ad is a seller whom actually said that he would not provide a bill of sale for a motorcycle he had with no title. His price was actually reasonable enough, that I might have bought it to part out, but there is no way I am ever going to bring home any motorcycle frame of any kind without either a title or a bill of sale to prove that it was purchased legally. The same goes for a Harley engine because some states will issue a title on the engine. If you won’t give me any paperwork to prove I bought it, well FYYFF I’m not going to buy it. Big Bubba down at the grey bar hotel ain’t near as fun to snuggle with as my old lady. Remember kiddos if you can’t at least get a bill of sale or receipt to show the man if he asks for it, walk away.

And finally, I guess we (myself included) should quit picking on the hipsters so much. Yes I know with their funky brakeless one speed bicycles & queer eye for the straight lumberjack style of clothing, they do make easy targets. But come on; give them some credit for their role in the current café racer, old school skinny tire chopper & bobber revival. They have dusted off a bunch of cool stuff from the past & are helping to insure its future. Plus without them, Pabst Blue Ribbon beer might have disappeared for good.

<bikers and hipsters too>

Then the old timer stepped down off of his soap box and the crowd cheered, although I don’t know if it’s because they enjoyed the lesson or just because the old man finally shut up. After he strapped the box back to his sissy bar, a rosy cheeked young man, with a long beard, in a flannel shirt handed him a cold PBR that he sipped on while chatting with the curious bikers who wanted to take a look at his ancient steed. When he had polished off the brew he crushed the can between his hand and his forehead and tossed it in the general direction of the nearest trash can, straddled his old chopper, twisted the grip three times and with a mighty heave on the kick starter fired it up. Once again the crowd turned to see and just as he rolled out of the exit, they all raised a cold one in a salute as the prophet sped away to the next gathering to preach his message of honesty, fair dealing, staying out of jail & caring for your fellow man.

 

Happy Trails Y’all

 

Happy New Year & A Quick Update

Just a couple of quick updates, I am still working on Project wAMMO but have been slowed down a little bit by life getting in the way, but tonight my favorite big brown van dropped off a nice little box from Dime City Cycles.

<Bates headlight & limp dick tail light>

Bates headlight & Sparto taillight

Hopefully I can get back to the shop this weekend.

Also over the next couple of weeks I’ll be adding a store page with some new & used parts & supplies for motorcycles. There may be some glitches at first so bear with me and give me a chance to get things sorted.

UPDATE; 1/1/17 store page removed

Peace Y’all

Big Changes for the New Year! UPDATED 2023

Dear Readers,

It’s now 2023 almost a decade later, it’s been a hell of a roller-coaster ride. I’m no longer running any business and just want to share my love and knowledge of motorcycles with the world. Coming back to WordPress to stay.

These last three years here at wordpress.com have been a blast, and I have loved every minute of it. If you are serious about blogging and are not running any kind of commercial enterprise from your blog there is no better way to get started than with wordpress.com.
Some exciting business opportunities have developed for me, and I now have dealership privileges for Shorai batteries, Rock Oil lubricants, & a few other products and wish to begin selling these products on my website, so I am switching to a different hosting service. You have my solemn promise to continue to bring you interesting and helpful content.
In the future I will focus mainly on motorcycles but still reserve the right to do a little bit of bicycle coverage sometimes. Be sure to bookmark this url and follow me to my new home on the web. It’s gonna be great!

Peace Y’all