Kawasaki STS engine cutting out

[Johnny Utah]

Just had a new engine from SBT installed, followed the break in instructions to the letter and it ran fine. The very next weekend it still runs but seems to cut in and out at around 6 RPM. Any ideas? thanks

[Technical Support]

Re: Kawasaki STS engine cutting out

That's usually ignition related. Try unscrewing the boots from the plug wires and snipping the wires back 1/4", then screwing the boots back on for fresh connections.

[Johnny Utah]

Re: Kawasaki STS engine cutting out

Do the black caps on the wire ends just unscrew from the small white connections at the electrical box or do you have to take the white colored connectors out? One of the white connectors that the plug wires screw into seems to be broken, could this be causing the problem? I had the same thing several summers ago and after replacing the small white connectors that were broken it seemed to help the problem. Thanks

[sah255]

Re: Kawasaki STS engine cutting out

I had a similar problem, the white external (threaded) plug at electrical box broke which allowed water into the electrical box and corroded all the connections especially those under the fuse block. In order to replace the white plug you need to disconnect the wire connector in the electrical box and either:
1. use a small screwdriver and release the male connections from the connector. This will allow you to remove the wires from the box without cutting them.
OR 2. Cut the wires at the connector, remove the wires from the box, replace threaded plug and splice wires back together with generic individual connectors
OR 3. Cut the wires at the connector and buy new connecotrs and pins from Kawasaki. I'm pretty sure you can buy the pins from an electronics store.