TOPIC:

Hello, a few months ago i acquired a custom cafe racer frame with the guts of a kz550 to put into it. i have the full wiring harness for it but it looks like a pain in the ass, is it better to just start from scratch or should i try and use the stock stuff.

What sort of shape is the current harness in?  What all do you wish to power on the machine, running a battery or not? Look you are there I am not. Its your budget for the project and not mine. In my way of looking at it it may be easier to make use of some of the current harness if in good shape than making a new one. But what do I know?

Good looking project, as GD4 says what shape is the loom in - as far as scratch building a loom that really comes down to your ability and confidence. I can give you links to calculate cable sizing etc if you want to go that route

The current harness is in good shape. there is no sketchy wiring and seems to all be stock. I just dont know how any of it goes since it came in a bin. 

looking to run a battery. as far as budget i am willing to spend the money on whatever it takes to get this thing going.

Here is a link to electrical system diagrams for many of the 550 models.

www.kzrider.com/filebase/category/62-kz550-electrical

If your engine came from a 1982 or 1983 model, you can look up the numbers here to determine which model it came from.

www.kzrider.com/filebase?task=download.s...id=1178&catid=64&m=0

Here is a copy of the factory service manual for the 1979 - 1983 550s.

www.kzrider.com/modules/ServiceManuals/Kz400500550_79to83.pdf

 

NoKnows wrote:

The current harness is in good shape. there is no sketchy wiring and seems to all be stock. I just dont know how any of it goes since it came in a bin. 

I would start by laying it out flat on the floor, lot's of guys on here have 550's so if you need photo's of the areas behind the panels I'm sure they will oblige

If you're not inclined towards electrical stuff I would advise to use the original harness.  You will need a wiring diagram that shows the wire colours.  This is invaluable when starting from scratch.  When you lay the harness on the bike, look at where wires terminate and think about what component goes there.  Ask for photos from members here to help where you are unsure.  Good luck!

Installing a wiring harness at first seems like a daunting task but they’re not that bad. Just put one foot in front of the other. In place of zip ties I suggest using black Velcro tape. You can reuse it when you change your mind about which way to run the wires. You can buy a big roll for cheap and it’s much kinder to the wires.

I would suggest you take a look at the links suggested. Wiring diagrams can be a great help. Just keep in mind the location of some items in the diagrams is not the actual location on the bike. But color of wires will show you what connections there are.and what systems are involved. There may be systems on the stock bike (harness) that you do or do not want on your project.