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It's been a long road but it will be worth in the end.
Steve

Got the headlight working.
Steve

Same problems so digging further.
Steve

I thought I had ruled this out. All this work will be worth it in the long run.
Steve

Ready for the Christmas ride.
Steve

Just curiosity question, here, since it sounds like you are getting this thing sorted out.... but, in both my 1977 factory service manuals, under MAINTENANCE- ELECTRICAL, there are circuit specific schematics. Does yours jive with those blown up schems, vs the "all in one" single page schematic? I think you've mention that you are using some parts from other looms? The only other harness/loom I have from one of my two partial parts bikes, is slightly different then my daily rider bike and the only difference I can tell is my driver was made in Japan in early October of 1976 and the other, I think, was USA and
March of 1977.

Adapting a KZ 900 harness to Z1 switches and indicators. They made changes even in the same years. Obviously there were other problems to deal with as well.
Steve

Did you get it home?

Doing maintenance after the trip.
Steve

I would be quite worrisome if I was using a quart of oil in under 300 miles.

After about 5000 miles on my 1075cc top end rebuild, ... sleeve bore and hone, pistons, rings, pins, head rebuild with new valve guide seals... etc... I'm still only using about 2-4 ounces every 2000-2200 miles, which is where I have always stopped and changed the oil and filter since the first year I owned the bike in 1977.
What do you suppose is the cause of this oil consumption, Steve?

Used rings/ valve guide seals.
Steve

With spark plugs out, are you seeing oil on the back side of the intake valves? A new set of +2mm rings is like over $100.00 plus the cost of a new base gasket and head gasket. A bummer and PIA in the winter... actually any time.