1975 KZ 900 , ZRX Swingarm, 89 GSXR front end

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:

:woohoo: :woohoo: :woohoo: :woohoo: :woohoo:

That was about 8 hours of troubleshooting. I kept thinking "it can't be the handlebar switch, that thing is brand new !!"

Never take anything for granted.

tk11b40 wrote: :woohoo: :woohoo: :woohoo: :woohoo: :woohoo:

That was about 8 hours of troubleshooting. I kept thinking "it can't be the handlebar switch, that thing is brand new !!"

Never take anything for granted.
...

I know what you mean. I installed new rebuild kits in a set of carbs and tried them out. One of the needle / seats wasn't sealing. Took it apart again and there was a big metal chip in there! Brand new....still should have checked it.

Lights look cool!

The tail light:
Made an aluminum mounting bracket for starters. I will get the plate mounts on it, then pull it and whittle it down to lighten it up. For now I am pre-fitting everything.

This is an LED taillight for a Ducati Monster S4R.

It is styled perfectly to fit under the tail section of the KZ. ... .... .... BUT I cannot get the brake light part of it to light up. Grrrrrrrrrrrr... Wiring sucks.

I have the identical taillight on my Ducati, and already know what wire goes where. I will keep fooling with it, but it looks like the brake light part may not be functioning. I'm bettin' Lockhart will not exchange it as it is an electrical part.

Anyway this is what it looks like on taillight mode, they are very bright and have the turn signals built in.

Well the brake light is working.. I don't have a clue as to what was wrong, but I works on both the front and rear stop switch. So I made the final refinements to the rear tail light bracket, and this is what I came up with.

I found an old bracket in my scrap pile, cut it in half and added another hole for support (the black brackets) to hold on to the signal lights. They now hang just below the tail-section.

Drilled all the mounting holes one at a time, then test fit everything. Took it all apart again, and added the wiring routing holes, then de-burred the whole thing. Took all day. It will be another month before I spend an entire Saturday working on the KZ..So how do these projects end up taking 10 years?

On to the head light. Anyone have a suggestion for the headlight brackets? As a last resort I will go to the Streetfighter stamped steel ones that wrap around the forks, but only as a last resort.

The bracket mounts to the same two holes which are in the underside of the tail section, they thread directly inot the frame.

Here is the final product:

Another view:

This is before I finished, so never mind all the loose wires. I figure if you are like I am and your trying to figure out a good way to mount the tail light and blinkers, you are probably looking at hundreds of KZ photo's. Hope this idea helps you if that is the case.

Gages ordered :

www.z1parts.net/product/kawasaki-kz900-k...hometer-assembly-mph

Horn installed and working.

Horn is set back about 2" from the exit (rear) of the oil cooler so you cannot see it.