85 GPz 750 Cafe Project

ajsfirehawk wrote: I'm using the existing harness. It appears most of the 'extra' wiring that will not be used will tuck up under the tank fairly easily. I'm not dead set on that, but that is where I'm headed now.

Idk what the differences are between 82 & 85 but the reserve lighting device might become a PIA if you aren't using factory switches or headlights. Short explanation, it senses if the headlight is working properly and will activate if it senses an element has burned out. If it's the low beam it will turn on high and add resistance to make it dimmer if it's the high it will automatically switch to low. It then turns on an idiot light on the gauge cluster.

I would delete it if you are not going to use one or more of the oem lighting, switch or instrument components. One or more of then will probably have resistance or current draw that will be outside the lighting device parameters and cause you problems.

On my bike the there are 3 blue wires: blue (power), blue/white and blue/yellow (hi/lo).
I cut the connector off the reserve box, twisted and taped those 3 wires together, tucked the others away put another layer of tape on it and plugged it back in to the harness- done.

Thanks for the thoughts. I am using the stock switch gear, but I'm using LED front and rear lights along with a new headlight. Sounds like trouble. I'll trace wires until I find out where this mystery module physically resides.

If you are going to use aftermarket gauges you'll probably need to delete it anyway.

This is what it looks like. It's probably somewhere around your battery or fuse block.

ebay.com/itm/1985-85-Kawasaki-Ninja-ZX75...054045598?nav=SEARCH

Double check the wire diagram too. The wire colors might have changed between my model year and yours.

Perfect! Thanks for the pic, very helpful. I'm headed out to tackle this in a half hour. I'll update end of day.

The Reserve Lighting Device doesn't exist on this bike anyway. It must have been sold with the other parts. Which is fine as it would be coming out. The headlight is rewired, I've started the instrument lighting. The connector kits I bought are for larger gauge wire than the new instruments. What Im keeping and what I'm discarding in terms of wiring changed three times this afternoon. Onward through the fog.

Any updates?

Well, not any good ones. A handful of unforeseen challenges. First was there is barely room for a petcock since I've lowered the tank to get the desired profile for the bottom of the tank and the bottom of the seat. Petcock actually hits the top of the carbs. Using a ZG1000 petcock with a Murph's Kit manual petcock conversion I'll be able to make it work.

The ZG1000 petcock should arrive this week. Meanwhile back at the ranch a small pimple appeared out of no where after being filled with gas for a few days.

It is a pinhole leak. I pulled a dent in that area and apparently created a leak. I've sanded it off, ruining the paint on the tank. POR 15 Tank Sealer after applying POR 15 Metal Etch will be the solution...along with a complete repaint. To say I'm bummed wouldn't scratch the surface of the emotions, but life goes on. While the tank will be functional, it will be homely as a mud fence until it warms up enough to repaint it. Likely next Spring. Took it out for a 5 mile ride and the jetting is still lacking. I've got 42.5 and 45 pilot jets sitting on the bench along with 135 and 137.5 main jets which will go into it after Thanksgiving. A bunch of family commits this coming week. All the wiring is sorted save the oil warning light which functions, but doesn't go out. I've got the wiring buzzed out and the oil sensor isn't changing state. Next on the agenda is to pull the oil sensor, disassemble it to see if it is packed with sludge or has a larger malady. Not the update I expected or wanted for something I expected to have delivered to the owner two weeks ago. Lightning bolts just seem to be dropping out of the sky, but I will beat them all into submission. It is just going to take more time.

Glad to hear that you are not giving up, if its any consolation I'm having more or less same issues with my build but I'm determined to keep going forward. That tank leak is a real bummer errrrr.

Back in the saddle, tore into the tank today. Dimpled the tank slightly, POR 15 Metal Etch, then a small fiberglass patch and POR 15 tank sealer. Also pulled the carbs and increased the jets to 42.5 for the pilot and 135 for the main to give me more fuel. Had to notch the #1 carb cover for clearance for the petcock. 96 hours for the POR 15 to fully cure.

That's the spirit! I'm really looking forward to seeing this one done.

Back at it again here and going to drive this across the finish line. I've decided I'm going to move the petcock location back a half inch since I have to redo the tank anyway. Fixed a headlight wiring issue, wired in the high beam indicator light and I believe that wraps up the wiring. After riding it late last season, the shock seals must have given out and the rear shock puked oil all over the garage floor. I've just finished replacing it with a ZR7s rear shock. Had to narrow the top shock mount bushing by 2mm and add two washers and a longer bolt on the lower mount. As this shock is 1/2 longer, I'm going to have to flip the chain adjustment bushings and move the axle towards the top of the swingarm or I can't use the center stand. The wheel and tire now set just a bit lower than the bottom of the center stand. Which brings up a question:
What is the best way to rotate the chain adjusters on an 83 to 85 GPz 750? I have to pound the bloody hell out of the to get them to budge. Pounding on things rubs my fur the wrong way. Yes I've loosened clamping bolts at the rear of the swingarm. What a massive PITA. Can't believe racing teams put up with this crap.