Suzuki 2 Strokes

Here's a quick question for you wizards on here. I have a Kawasaki G3SS 90cc bike toally restored and running well beside one nagging problem. First off I apologise for posting about a Kawi but I think you guys may have run into this before. The bike has a 6volt system. One coil supplies the spark and is independent from the charging system. The second coil goes straight to the handlebar Hi/Lo switch and to the headlight and hi beam indicator light. This coil is not connected to the charging system or battery either. The third coil has two taps, one is low power for daytime battery charging the other for hi power charging for night time riding. This third coil goes straight to the reg/rec. Looks like the turn signals, brake/tail lamps, and horn get juice from the battery.

Here's the skivy, bike starts and runs good on daytime setting, turn to night time setting and bike starts sputtering at idle and won't clear out or rev when riding it.

I have replaced the headlight and charging coils, checked wiring etc...

What I can't understand is how a charging/short in the headlight circuit could affect the ignition circuit. It's independent from everything else just a coil, breaker, switch.

Thanks!!!

Quick pic of it.

We might have some suggestions if you post a wiring diagram.

Have you looked into any of the Kawasaki forums?

I was going to ask for a schematic but you beat me to it. If you can post one up for that model tunaglove that would be very helpful.

Will do. I have the PDF schematic ,trying to learn how to post it!!

Well the problem is solved. Sorry I did not post a schematic, it is very similar to the TS90 schematic in another post here.

I double checked all of the wiring using an ohm meter and schematic. The wiring was correct but some connections where corroded. This helped but did not totally fix it.

Next went through grounding and found many spots covered in paint like behind the ignition coil and between the frame and motor. This helped a little more but it still stumbled with the headlight on.

Then I found a NOS magneto for cheap and tried it. The original magnets must have been weak or something because this seemed to do the trick.