Uploaded March 2021 | Updated September 2026, 2 weeks ago
The Broken Moto Show - Episode 31 - Chop, Cut, Rebuild
Submit questions to: askbrokenmoto@gmail.com
motorcyclemd.com
howtomotorcyclerepair.com
Enjoying The Broken Moto Show?
You can now show your support by
BUYING US A BEER!
howtomotorcyclerepair.com/codymattbeer
Try Grip Clean products for yourself and tell us what you think.
Use the code “MOTOMD” at checkout to get 10% OFF your order at
gripclean.com
Need more in depth help with your bike? The MotorcycleMD Inner Circle may be exactly what you need. Find out what it’s all about here: themotorcyclemd.com/mcmd-inner-circle-member
Follow MotorcycleMD on Instagram at
/themotorcyclemd
Question 1: 2002 Kawasaki ZR750, Is there a way to wire in the headlight to come on with key-on power like the rest of the lights do, upon startup.
Answer: Absolutely. The key to do this is to figure out what wire leaves the relay once the bike is started that is supplying power to the headlight bulb. Then taking a jumper wire to bypass that wire to something that has constant power with the key on. Like the 12v wire that is powering the relay itself.
Question 2: Kawasaki VN750 Follow up. The problem that was presented back in episode 3 was an issue with the bike now revving over 3,000rpm. We suggested going back through the carburetor system as this would be the cheapest route to take for diagnosis.
Answer: Replacing the CDI/ECU solved his issue completely. So he likely had a pulser timing issue with spark or an issue with spark cutting or becoming erratic at that RPM.
Question 3: Yamaha V-STAR 650. What is the blue connector for in the headlight?!
Answer: No idea. Try sending us more info with the schematic you're looking at and some pictures of the color wires you're asking about.
Question 4: Kawasaki KX250 Bike is stalling when shifting into gear and giving it throttle
Answer: Making sure your freeplay and cable adjustments are correct is vital. It does however sound like you could have a clutch assembly issue. Pull the clutch apart and have a good look at the color of the metal parts to spot any overheating or misassembly issues.
Question 5: Bearing removal tools?
Answer: Matt uses a nice set up from TUSK = amzn.to/2Q9XXNI
Another good brand is Motion Pro = amzn.to/3cEMJZa
Enjoying The Broken Moto Show?
You can now show your support by
BUYING US A BEER!
howtomotorcyclerepair.com/codymattbeer
Thanks!
The Broken Moto Show - Episode 31 - Chop, Cut, Rebuild
Submit questions to: askbrokenmoto@gmail.com
motorcyclemd.com
howtomotorcyclerepair.com
Enjoying The Broken Moto Show?
You can now show your support by
BUYING US A BEER!
howtomotorcyclerepair.com/codymattbeer
Try Grip Clean products for yourself and tell us what you think.
Use the code “MOTOMD” at checkout to get 10% OFF your order at
gripclean.com
Need more in depth help with your bike? The MotorcycleMD Inner Circle may be exactly what you need. Find out what it’s all about here: themotorcyclemd.com/mcmd-inner-circle-member
Follow MotorcycleMD on Instagram at
/themotorcyclemd
Question 1: 2002 Kawasaki ZR750, Is there a way to wire in the headlight to come on with key-on power like the rest of the lights do, upon startup.
Answer: Absolutely. The key to do this is to figure out what wire leaves the relay once the bike is started that is supplying power to the headlight bulb. Then taking a jumper wire to bypass that wire to something that has constant power with the key on. Like the 12v wire that is powering the relay itself.
Question 2: Kawasaki VN750 Follow up. The problem that was presented back in episode 3 was an issue with the bike now revving over 3,000rpm. We suggested going back through the carburetor system as this would be the cheapest route to take for diagnosis.
Answer: Replacing the CDI/ECU solved his issue completely. So he likely had a pulser timing issue with spark or an issue with spark cutting or becoming erratic at that RPM.
Question 3: Yamaha V-STAR 650. What is the blue connector for in the headlight?!
Answer: No idea. Try sending us more info with the schematic you're looking at and some pictures of the color wires you're asking about.
Question 4: Kawasaki KX250 Bike is stalling when shifting into gear and giving it throttle
Answer: Making sure your freeplay and cable adjustments are correct is vital. It does however sound like you could have a clutch assembly issue. Pull the clutch apart and have a good look at the color of the metal parts to spot any overheating or misassembly issues.
Question 5: Bearing removal tools?
Answer: Matt uses a nice set up from TUSK = amzn.to/2Q9XXNI
Another good brand is Motion Pro = amzn.to/3cEMJZa
Enjoying The Broken Moto Show?
You can now show your support by
BUYING US A BEER!
howtomotorcyclerepair.com/codymattbeer
Thanks!
