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Wire gauges, connectors, etc - kz650

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28 Dec 2020 08:49 #840717 by katit
Hello All!

In preparation for full resto of my kz I am researching what will be needed. Looks like there is many "bullet" connectors around a bike. Is it good idea to keep same style ? If so, where do I get good quality ones?

Another question is wire gauge. What gauge used through the bike? I have large supply of nice 18Ga wire and wonder if this will do.

What about modular connectors? Is factory style available and where I can get those?

78 KZ650B2A - resto in progress
www.kzrider.com/forum/11-projects/615161...s-1978-kz650-project
Other bikes: 1978 BMW R100/7, 1978 Moto Guzzi T3, 2016 DRZ400s

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28 Dec 2020 09:48 - 28 Dec 2020 09:48 #840720 by martin_csr
Replied by martin_csr on topic Wire gauges, connectors, etc - kz650
CycleTerminal.com has stock-type connectors & terminal pins and they have a 10-pack of waterproof bullet connector sets. plus other stuff. I got most of my electrical supplies there plus a terminal pin extractor tool set >> white handles. I already had a ratcheting crimper from HF, but the dies were wrong, so I got an open barrel die set from Aircraft Tools on amazon.

Z1Enterprises.com also has connectors & terminal pins plus color wire. Both places have good ratcheting open barrel crimpers >> the crimps are very strong.
Last edit: 28 Dec 2020 09:48 by martin_csr.

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28 Dec 2020 09:49 #840721 by Mikaw
Replied by Mikaw on topic Wire gauges, connectors, etc - kz650
I have had good luck with vintage connections

1976 KZ 900 A4 kzrider.com/forum/11-projects/613548-1976-kz-900-a4
1976 KZ 900 B1 LTD
1978 KZ 1000 B2 LTD
1980 KZ 750 E1
Kowledge Speaks, But Wisdom Listens.
Jimi Hendrix.

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28 Dec 2020 09:53 #840722 by katit
Replied by katit on topic Wire gauges, connectors, etc - kz650

martin_csr wrote: Both places have good ratcheting open barrel crimpers >> the crimps are very strong.


I have greenlee pa8024 crimper, I think that should do.

Thank you for store pointers!

78 KZ650B2A - resto in progress
www.kzrider.com/forum/11-projects/615161...s-1978-kz650-project
Other bikes: 1978 BMW R100/7, 1978 Moto Guzzi T3, 2016 DRZ400s

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28 Dec 2020 10:08 - 28 Dec 2020 10:10 #840723 by F64
Replied by F64 on topic Wire gauges, connectors, etc - kz650
You'll have to figure out how much current each wire will see then account for a little more.
The fuses are meant to protect the wire not the load so choose your fuses based on current capacity of the wire.

Wire calculator
www.wirebarn.com/Wire-Calculator-_ep_41.html

I source my wire from prowire
prowireusa.com

I use Deutsch connectors but that may not look right with your restoration and may be overkill.

81-KZ440-D2.
Louis Dudzik's GM HEI ignitor conversion installed 2015 s3.amazonaws.com/gpzweb/Ignition/GPZgmHEImod.html
Motogadget m-unit blue installed 2017.
LIC, NY
Last edit: 28 Dec 2020 10:10 by F64.

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28 Dec 2020 10:37 #840724 by katit
Replied by katit on topic Wire gauges, connectors, etc - kz650

F64 wrote: I use Deutsch connectors but that may not look right with your restoration and may be overkill.


I was curious about "general use" wire gauge. Seems like 18Ga is what Z1 sells, it can handle little over 5A current so should be good for most systems in a bike.

Connectors is a dilemma for me. I feel like I need to preserve all "ends" like stock to make any parts replacements plug-n-play. So, those bullet connectors might have to stay (even though I don't like them). It also makes sense because it's much easier to fish those bullets through tight spaces vs bulky plugs.

78 KZ650B2A - resto in progress
www.kzrider.com/forum/11-projects/615161...s-1978-kz650-project
Other bikes: 1978 BMW R100/7, 1978 Moto Guzzi T3, 2016 DRZ400s

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28 Dec 2020 10:47 - 28 Dec 2020 10:49 #840726 by martin_csr
Replied by martin_csr on topic Wire gauges, connectors, etc - kz650
By katit: I have greenlee pa8024 crimper, I think that should do. ...

Okay. I couldn't find a good pic of the PA8024 to see what type of dies it has.
I forgot to mention that the tool I use does stock-type crimps.


Last edit: 28 Dec 2020 10:49 by martin_csr.

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  • hardrockminer
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28 Dec 2020 10:48 #840727 by hardrockminer
Replied by hardrockminer on topic Wire gauges, connectors, etc - kz650
I think this is the place Mikaw mentioned. I use them all the time. They have connecters, wire, sleeves and even a very good crimper tool.

www.vintageconnections.com/

I have several restored bikes along with a 2006 Goldwing with a sidecar. My wife has a 2019 Suzuki DR 650 for on and off road.

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28 Dec 2020 13:49 #840737 by F64
Replied by F64 on topic Wire gauges, connectors, etc - kz650
I wouldn't sign off on 18 awg only. At least, I would measure the wire you have on the bike currently . You have to measure the conductor minus the insulation.
Most of the bike could probably be wired with 18 but there are some areas where you may need bigger.
Plus, you should account for any upgrades that you may want to do in the future.

I would stick to the stock bullet connectors.
The Deutsch pins are actually smaller than the bullets and are pretty easy to remove from the connector housing if you have different project in the future.

81-KZ440-D2.
Louis Dudzik's GM HEI ignitor conversion installed 2015 s3.amazonaws.com/gpzweb/Ignition/GPZgmHEImod.html
Motogadget m-unit blue installed 2017.
LIC, NY
The following user(s) said Thank You: katit

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28 Dec 2020 14:56 #840747 by Mikaw
Replied by Mikaw on topic Wire gauges, connectors, etc - kz650

hardrockminer wrote: I think this is the place Mikaw mentioned. I use them all the time. They have connecters, wire, sleeves and even a very good crimper tool.

www.vintageconnections.com/


Thats the place, thanks for posting the link. I was replying on my lunch and didnt have time to post it.

1976 KZ 900 A4 kzrider.com/forum/11-projects/613548-1976-kz-900-a4
1976 KZ 900 B1 LTD
1978 KZ 1000 B2 LTD
1980 KZ 750 E1
Kowledge Speaks, But Wisdom Listens.
Jimi Hendrix.

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28 Dec 2020 16:15 #840749 by richard-GPZ
Replied by richard-GPZ on topic Wire gauges, connectors, etc - kz650
If you are not worried about making it all original you might consider a Moto Gadget M-Unit.
shop.revivalcycles.com/motogadget-m-unit-blue/
The M-Unit updates many of the electric circuits on your bike.
It is a replacement for your junction box.
I am currently installing one on my 83 GPZ-1100 .

1983 GPZ-1100 completely stock

1983 Gpz-1100 hot rod build in process

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28 Dec 2020 16:17 - 28 Dec 2020 16:17 #840752 by riturbo
Replied by riturbo on topic Wire gauges, connectors, etc - kz650
This place has a lot of stuff too.

cycleterminal.com/

Gpz 750 turbo The one I ride
Gpz 750 turbo Not finished
Gpz 750 turbo Not started
Gpz 550 1981
Gpz 550 1983
Bunch of other junk
Last edit: 28 Dec 2020 16:17 by riturbo.

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