1975 KZ 900 , ZRX Swingarm, 89 GSXR front end

Very interesting. I converted a new Z1 rh switch to work on my MKII. I wired it so the PO is like parking lights, tail light and running lights but no headlight. Then I have On and Off. Couldn't turn off the headlight the way it came from Kaw.

PO stands for "Pissed Off that I did not take better notes" when I took it apart ten yeas ago.

J/k.. I have learned some things so far, the blue wire is hot for all lighting. Black with yellow stripe is ground for all lighting. What I thought was the brake switch for the rear is actually the flasher for signal lights.

The diagram you posted is the same one I am using as a guide, but mine is paper and about 20 years old. So tomorrow at work I will make an 11x17 print of the file you have posted here, that should really help.

It is just going to take time. I have all the wiring from the center of the frame back to the tail figured out. The turn signals front and rear , and the headlight.

I think the instrument lighting is all that's left. I am putting printed labels on the ends, so I can double check as I install lighting.

Some of it is just freaky though. Like there is a single blue wire that goes from the head light switch over to the other handlebar switch, into a double. The diagram shows no doubles, so I just hook it up and hope the fuse does not blow. Why you would need one wire to cross over is well..strange.

I am going to install a 10 amp fuse so if I short anything I will know right away without damaging anything.

I have only One fuse, a 20 amp main on the white main power wire. I think the other three fuses went away when I installed the new regulator rectifier. That blows me away too, the bike in stock form has three fuses, so what are the other two protecting?

Thanks for the help. This is going to be a long puzzle.

Wiring bites donkey ass!!!
The double socket for the blue wires is on the diagram, right close to the "Headligth switch". One blue wire is spliced into a red wire that comes out of the head ligth switch, then goes into a blue that goes into the double socket, and carries on in a different direction as red, into another blue. Ya!! frik!!
I ended up buying origianl handle bar switches, and complete wiring harnesses. Was having TOO many issues with wiring!!
The Z1 900 only had the one fuse (20 amp) off the main wire from the battery. That is all this bike ever had.
The KZ900 and KZ1000 used a 3-fuse block. These appeaered in 1976.
Z1 900 and KZ900 harnesses are different.
I ran into this fuse block problem, my bike came in a couple boxes of parts. And, a couple badly spliced together wiring harnesses!!
Best way to figure out what engine/ frame you have is by the numbers:
For example:
my frame is a Z1F 71862. This 5 digit number signifies that my frame is a 1973 Z1 frame.
my engine is a Z1E 072047. The Z1's production line started with Z1E047500. My engine number indicates that my engine is a late model 1975 production.
So, I have a 1973 frame with a 1975 engine.
1975 Z1's had the elctrics all on the right hand side of the battery holder.

When you get into the wiring for the rectifier, generator, regulator blah, blah, blah.... I had all from different model and year of bikes. From what i understand they all do the same thing, and are interchangeable amongst the years and models, but the wiring attached to them are/ might be different colors. Just a little more to confuse things!

Z1 Enterprises is a great source for parts and knowledge. If you ever get completely stumped!

I think that blue wire going to the other side of the handlebars is for the starter lockout switch on the clutch...it's in series through several switches....kill switch, starter button, clutch switch...... Not even sure the Z1's had the clutch switch actually..... :S

:ohmy: :ohmy: :ohmy: :ohmy: :ohmy: :ohmy: :ohmy:

Well...
I have most of them figured out now. But there is a few curves. I definitely have a Z1B model 1975. The rectifier, and regulator are all wired in correctly. I am very glad to hear the bike had only one fuse.

I bought the handlebar switches, and the wiring harness from Z1 Enterprises. I would have thought they would come with a diagram but do not. I am going to keep after it labeling each wire as I go.

Hopefully Z1 Enterprises has a schematic available. Oddest part o figure out is the location of the connectors, the wiring diagram just does not tell you where they might be.

A routing diagram would be awesome. After a month or so of searching for one, i winged it. lol. The harnesses off the handle bar controls were long enough to run down into the area above the horn, thats where I made those connections. The turn signal flasher I mounted just south of hte battery, by the tool tray. Main harness from the original gauges that I used (2 harnesses out of this unit) I left them behind the headlight bezel.
If you are making your own harness, you can pretty much put them where ever you want.
Here's a couple other things that I pondered on for a while...
in the first picture (1.jpeg), this is from the wiring diagram you are using, the blue box is the turn signal flasher, the black box was for hazard lights.
in the second picture (0.jpeg) this was mounted right under the fuel tank, just south of the coils. Brake Light failure box. And there is a corresponding light on the original speedo for this.

Here's a couple websites I have looked at that seem helpful for parts, some pretty good diagrams (the first one I thnk is a great source):
www.classickawasaki.se/Tekndokument/Parts_Katalog_Z1B_1975.pdf
www.cmsnl.com/kawasaki-z1-b-1975-usa_model14521/partslist/
www.partzilla.com

Here is a very interesting video I found.
While it does not help me too much it may help others.

Made in the 70's by Kawasaki to train factory techs:

The whole series !!

Ok Need help again !!

I am down to the horn and the turn signals, the horn I will worry about last. The turn signals:

Reasonably certain I need two flashers, one for the turn signal, and one for "hazards". It looks like the two are linked, so if you do not have one, the other will not work. I have purchased a solid state flasher for the LED turn signals, this unit plugged in does not flash, nor do I have power at the signal light connectors.

I have attached a photo of the hazard relay on the wiring diagram. I do not have anything like this on my harness presently, should I have one? There is one brown connector near the fuel tank, and it looks like it should be hooked up to this hazard relay, but I don't see the Red or the orange wire anywhere near it.

I surfed the electrical forum, and saw a very similar issue.

This is the current set-up....

Someone please tell me what is wrong here, it looks OK to me.

I need some Scotch now....

I am not into dogging the vendors that support our hobby. But never take anything for granted, so I decided to dis-assemble my brand new turn signal switch..and look what I find. The orange wire is common to both left and right, it provides power when switch from let to right.

Orange wire was just inside the switch housing floating about, no longer connected to the directional switch. I will now re-solder this and see if it works.

AHHHHHHHHHHHHHHHHHHHHH

All fixed !! it was the broken orange common wire inside the handlebar switch. I hope the forum does not mind foul language..but that was a bitch to figure out, soldering it was also very interesting. Wooo- hoo glad that is over.



If you are wiring up LED lights here is the way my LED flasher is hooked up to the stock KZ: