'78 KZ650SR. No Spark. No Pop. No Fireworks.

My current project 1978 KZ650SR is moving along. (as I push it)

Carbs are clean and re-installed. Now I need to address the electronics. Key on, known good battery, kill switch on, no obvious hacks in the harness, but ... no spark.

I pulled the cover off and the points look ok.

Suggestions welcome of where to begin probing with my meter or just buy a new set of coils and an electronic ignition ...

Random photos:

 

Voltmeter on Vdc setting
Red lead to coil feed (yellow/red) black lead to battery ground - ignition on, kill switch on should read within 0.5v of battery voltage
Now without moving the meter leads crank the engine - voltage should drop no lower than 9.5v - 10.0v
Now move the black meter lead to the switched side of the coil - when the points are closed should read close to battery voltage - rotate the engine until the points open - voltage should drop to close to zero (it is the point when you "break the ground" that the coils spark)
If that all reads ok switch meter to resistance, disconnect coils and measure both primary and secondary resistance follow manual for process and spec (I would expect 3-4 ohms on the primary and 10 to 15,000 ohms on the secondary)

Thanks. I need to find a manual for the 1978 SR. The manual I have is for 1980 and much is different.

Found this on the internet, searching "KZ650 factory service manual"

files.ecommercedns.uk/221472/1d01f011b29...a5f7d77eaa93d650.pdf

Not specific to the SR, but lots of good info about the early ignition system.

If you are seeking a Kawasaki Service Manual that covers the D model these are the Part#s that do cover them.

99924-1001-02
blue cover
Candy Super Red B1 on cover
C1,C2,B1,B2,D1

99924-1001-03
blue cover
Candy Super Red B1 on cover
B1,B2,B3,C1,C2,C3,D1,D2

99924-1007-01
Blue cover
Luminous Dark Blue B2 on cover
B2A,D1A

99924-1007-02
blue cover
Candy Emerald Green B3 on cover
B2A,B3,C3,D1A,D2


99924-1007-03
Blue cover
Candy Emerald Green B3 on cover
B2A,D1A,B3,C3,D2,B4,C4,D3,E1,F1

99924-1028-01
dark blue or black cover
Sundance Blue H1 CSR on cover
D4,F2,H1 

99924-1028-02
red cover
Ebony H2 CSR on cover
D4,F2,H1,F3,H2 

99924-1028-03
Maroon cover
Ebony H2 CSR on cover
D4,F2,H1,F3,H2,F4,H3
 

How do I discern which model '78 650SR is mine?

The frame number should help with that. Does it still have a white sticker on the neck. If so it should have a month and year build date, if it is a 78 model/year bike it is either a D or a D1A. The D1A came stock with smaller carbs as the major change in the models. Though I will not claim the attached table to be 100% correct here are frame and engine numbers I found in the past. Make of them what you wish.

Sticker on the neck says build date 9/1978.

Frame number: KZ650D-013726

Engine KZ650DE013885

The build date and the frame and engine numbers would make it a 1979 KZ650 D2 and not a year earlier D1 or D1A.

Does anyone know what the reason was for all the different 650 D models?

And which is the service manual specific for my 1979 KZ650 D2 ?

chopper1963 wrote:

Does anyone know what the reason was for all the different 650 D models?

And which is the service manual specific for my 1979 KZ650 D2 ?

There are several reasons for the different designations.
One reason is to identify the particular model.
Another is to simplify life for folks responsible for inventory, parts and such. The marketing folks might want to give that model a really catchy name like, the Hyabusa Telluride GTS/R 652. Some poor goober would have to type that long name in every time they were dealing with some tiny part, or counting bike inventories and such. Those folks would be a lot less pissed off if all they had to thpe was D2.
Anoher reason is to clearly and simply identify the model year, which is different from the calendar year. In order that dealers can have a showroom full of 1978 models on, or even a little before, January 1, 1978, Kawasaki has to start actually building those machines in 1977. The change often happens in July. Giving each model year a simple, one or two digit number makes life much less maddening for owners and parts folks alike. The D1 was the first model year production of the model D. Since Kawasaki offered new colors each year and it made constant improvements to each model, a simple designation like D1 makes getting the correct parts years later a much less complicated process.
Ocasionally, the U.S. gubmint would introduce some new safety, noise or pollution regulation, necessitating a mid-production change, or for some internal reason the company wanted to make some change, and the result is an additional designation like D2A. 
Searching for a rear fender bolt for a 1979 KZ650 D2A seems less annoying than asking for a late production 1979 Kawasaki Hyabusa Telluride GTS/R 652 rear fender bolt for the updated noise-reducing fender design for the U.S. market, with the polished head.

Most of the factory service manuals have a chart on the back cover listing the exact models covered in that version of the book. Otherwise, you will have to look inside to see which ones are covered.