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Repairing the 2002 Kawasaki 650 Belt Drive Failure Detection SystemJanuary 17/05 Written by Joebear I have a 2002 Kawasaki 650. The reverse light came on, and no matter what I did, it stayed on. The rev limiter kicked in too. No 4wd. I was 20 miles from the truck, in the mountains, with the wife on board, and pulling a trailer. I had to hold the override switch to get full power but I still only had 2wd. Luckily, we made it out with no problems! I taped a small stick to hold the switch in while I rode, as my thumb was getting really tired. After getting home I went through the manual, checking everything I could. The test on page 16-75 "Drive Belt Failure Detection System" is the one that failed. There is a diode in the wiring harness above and to the right of the fuel petcock. As far as I can tell, this is only on the 02 model. It is wrapped inside the wiring harness, so you have to pull it out to repair it. The diode had shorted so it was acting like a regular piece of wire, allowing voltage to flow both ways instead of only one way. The Kawi dealer had nothing in the parts list on this diode, so off to Radio Shack I went. A 1 amp diode and a 3 amp diode were given to me to try. I put the 1 amp diode in and it has been in there ever since. I siliconed over and around it and taped the harness back up. The diode is polarity-sensitive; make sure the stripe/band on the new diode goes on the same side as the stripe from the old diode. I carry the 3 amp as a back up for when I go riding. Note from Greg: I'd recommend installing a 3A diode. The price difference is negligible, and the leads are thicker. I'd shorten the leads, solder it in place, and cover the whole mess with rubber heat-shrink tubing. The electronic part number for this diode is 1N4003. It's a common part at any electronics supply store, and will cost you less than a dollar. |
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