'81 KZ650 Rewire

[MNBikerPup]

Hey Guys, I could use some advice/help. I have a '81 KZ 650 in which I need to rewire due to a hack job on the bike from previous owner. My budget is very small. I did pick up a wiring harness from a car at the boneyard, so I got the wire. Now, the main question. How do I go about rewiring the minimum? As in, I want the bike to start/kill, headlight and tail light and turn signals, and a horn (for legal issues)? I don't need lights to tell me I am in neutral, or if my highbeams are on or anything like that. But, I also want to wire in a couple of accessory connections for future electrical connections should I want to add later on. Thanks for the help guys.

 

[Big R]

Have you tried www.oldmanhonda.com? He has an interactive wiring diagram that may be useful to you.

 

[hillsy]

If your bike is not already registered / inspected / whatever, you might need things like neutral and hi beam lights to get it passed.


Just sayin...

 

[teazer]

Good start with getting a bundle of wires cheaply in many different colors.

Sometimes it's easier to repair a hack job than to start again. Either way, you will need a good wiring diagram.

One technique that works is to take multiple copies of the wiring diagram and highlight one circuit on each copy and then follow that one onto teh bike. Then move to a second circuit and slowly the picture builds, as does the loom.

I'd start with power from the battery through the switches first and then go out from the main switch to the ignition circuit. When that's good, do the starter because it uses the same right switch block.

Next I'd do the headlamp wiring through the left switch block and tail lights. Then indicators and then the charge circuit.

But back to the beginning. How bad is the original loom?

 

[Bozz]

I'm with Teazer, unless the loom is completely fried start there and re-create if you can.

Although a new harness can be less complex, it takes some doing.

Whatever you do, don't forget to fuse your main, ignition, headlight/tail light and signal circuits.

IT can be done and it isn't necessarily rocket science.

Logic and patience are your friends.

 

[MNBikerPup]

The harness is hacked from the all the handle controls, ignition coils. Starter solenoid is still attached, ignitor and rectifier still attached to the battery as is the starter. Signals are totally detached. (I opened up the harness to see where I was at because everything going to the left and right handlebar switches, ignition and headlight hacked off)