I picked up a 04 kfx80 for my kids as they are too sissy to ride the cfr50 or pw50 without training wheels and demand 3+ wheels.... whatever, they will learn the two wheel way in time.

bike ran like a champ when i bought it hauling my 200# *** around nicely. Brought it home late at night and was riding out front and hit a nice short pole set in concrete and Jacked my knee badly.
whatever the case... started up with some difficulty the next day and ran great, once on a slope it started to act like the plug was fouling so I tried to rip it down the road and it left me stranded with crank but no start condition and I had the pleasure of getting it home with my jacked knee...

Next day... the starter will not engage and the relay ust clicks. I Discover that the ******* PO had cut and removed the circuit breaker...
order a new battery, petcock, and relay, install all still no crank but noise at the starter. Attempt to hit starter as cranking to see if windings are shot... starter arcs and new relay is toast.

pretty lame that these didnt come with recoil starters from the factory...

what do you think the issue is? Starter went out? Bad petcock caused an issue?

can you push start these suckers with another machine?

if starter, looks like a real bitch to replace. Any tips/tricks?

and almost most importantly... does the circuit breaker just go between the hot leg to the relay? Or how do I need to put that back in play?

thanks much to all who have constructive comments!

robert

 

I'd have the starter load tested...they are in a crappy spot and are subject to water contamination. They can't be push-started (automatic), but you can, and I highly suggest, you get the backup recoil. Electrical stuff dies & leaves you stranded...manual recoils don't


If starter checks out then it's time to get the ohms/voltage tester out and go to work...

 

I'm wondering if the motor got flooded (carb leaking fuel buy the float needle) and locked the motor up.
Did you pull the plug and try to spin?

 

Thanks for the responses. It was indeed flooded by the defective petcock. I put a recoil on and after about 15 rips it was all cleared and fired right up.

Do you guys know where the circuit breaker goes? Is it just in line with the hot leg to the starter relay?
I have the breaker out and would like to put it back in...

 

On mine the fuse is on the harness near the battery...

 

Not the fuse.. The circuit breaker located under the right side rear fender... PO cut it out and it was just mounted, but not connected. I want to get it put back into play.

Thanks!

 

Oh...you have the newer one...I'll have to find ya a wiring diagram...

 

That would be awesome man.

Hey, you know where I can find a service manual. This is the first bike out of probably 25 I have owned that I can't seem to find one free online...

 

Do you have an email address? I can send you one...

 

thx! You're the man!
rvh@***.net