Splicing Kawi controls to Honda harness HELP

[dmable44]

So I am running a set of ZX600 carbs on my 81' CB650. I ran into some throttle cable issues so I got the Kawi controls with the throttle cables. That issue is now solved. I now need to figure out a way to plug the Kawi controls into the Honda harness. Here is a picture of the different plugs, the green is the Kawi and the red is the Honda. Any help would be great!

 

[irk miller]

Go to Vintage Connection, http://vintageconnections.com/ Click on the Prices tab and scroll down the page to the nylon connectors. They sell them as matching male and female. You will also want to get a set of metal connectors and redo them, as well.

 

[Tune-A-Fish]

Umah add it to my parts thread that shud be stickyfied

 

[dmable44]

Sweet thanks for the link. But how do I know which wires to connect from the Kawi to the Honda? Also, the Honda has more wires than the Kawi.

 

[irk miller]

Sweet thanks for the link. But how do I know which wires to connect from the Kawi to the Honda? Also, the Honda has more wires than the Kawi.

You're going custom, so you'll have to approach it that way. My suggestion is to get a male/female connector and redo both sides. I'm not sure what the extra wire is for, so it's hard to suggest what to do with that. Maybe wired separately with a bullet connector.

 

[dmable44]

I've been looking over the wire diagrams for both bikes and since I'm not electrical savvy , I can't really determine which wires are compatible.

 

[teazer]

Yes you can.

Start with the switch and determine what wires do what. The way I do it is to open the switch to see which colors go to which part of the switch. Don't pull it all apart, just split the two halves so you can see which leads go to the light switch or horn button or whatever..

Then grab a multimeter - doesn't need to be a top of the line megabuck fluke. A simple cheap one will do the job and if not - grab a small battery a light bulb and some wire or grab a continuity tester from your local parts store. Before you start testing for connectivity, get a nice new pad of paper and a pen or pencil. Lots of paper - not just n old envelope.

Test each circuit and test for all the leads. Say for example that you see say a green and yellow going to the starter button. Put one lead on that color at the plug end and test EVERY other lead to see if it connects. Then push the button and while holding it in, re-test all the leads. Let's say it connects to a brown lead when the button is pressed and to no other lead when it's not pressed.

Stop and draw two leads on one sheet of paper and write down the colors and draw a switch that is normally open.

Repeat for every color of lead until you know what they all do.

A little trick is to carefully remove all those pins from the connector housing. You can then put them into a different shaped connector housing in a sequence that matches the loom. You do not need to cut them all off unless the loom is too long and needs to be made shorter.

Then grab the wiring diagram for the bike and work out one circuit at a time and draw those out one at a time on different bits of paper and then compare the switch to the loom and see what can be made to match and what is missing.

Take your time and it becomes quite simple.