KZ750 where do I start rewiring?

I've gotta start by saying this site provides a wealth of information. I just bought a '81 KZ750LTD that was running, but had some issues with the taillights/rear turn signals shorting out. As I started looking at the wiring, I found some chaffed and cracked wires coming out of the harness. I also changed out the master cylinder with a newer version. The old one didn't have a switch mounted behind the lever. The newer one does. The more I've explored, the more problems I'm finding. It looks like previous owners tried to rewire by going crazy with multiple six inch splices in a single line. I have completely unwrapped the harness so all wire splices are visible. Now, every time I turn the key over, the 20A fuse coming off the positive terminal fries immediately. Also, the ignition switch that is on the bike is not the original. It does not match up with the schematic I got off this site. I traced out all of the wires coming off the switch today and have it all identified so I can translate the schematic.

Long-winded, I know, but here's the question. I want to completely reaccomplish the wiring to clean up chaffed wires, wires that run the length of the bike and go nowhere, and to eliminate whatever is causing the fuse to blow. What is the best way to begin. Thanks a million for any help that can be offered.

Duggie

Here's where I would start: Harness

Post edited by: 650ed, at: 2008/01/02 13:25

WEEEEE-ooooooo-WEEEEEEE-ooooooo...

...it's the link police. Your link is offensive. Be glad I didn't quote it!

:laugh:

Here is your fixed link ...

Just buying a new harness is not very fun or educational. This is my first winter project bike. I am a rookie at this restoration thing,so bear with me if I have moments of dumbness throughout the winter. Thanks guys.

Duggie7mag wrote:

Just buying a new harness is not very fun or educational....

Well, yeah, that's true enough. However, it might still be a good idea, but I see where you're coming from.

The first thing you need to do is get a wiring diagram, and some line testers and start tracing every connection. From the sounds of it, you'll end up replacing some (if not alot), and you'll need to make sure you use the correct gauge wiring. There are always arguments here as to whether or not to use bullet connectors or solder. There was a great thread just a while back about this debate, and a few links to classic-style connector retailers.

Remember, much of that old wire will be corroded, especially around the connectors. And you may not always see where the corrosion is, either, as it may be deep inside the sheath....

Good luck!

OK Link Cop, you caught me red handed. Where do I find the instructions on how to modify a link so it isn't a zillion characters long?

Thanks!
Ed

Not sure if it's what Bisque uses, but I use
www.tinyurl.com

Nope, I detest tinyurl. I appreciate what people are *trying* to do by using it, but I would never click on a link that I could not see where it's taking me. I know there are plug-ins for Firefox that will help with that, but still it's the point...

With a forum-style link you can at least hold your cursor over it and see at the bottom of the browser where its going to go...

Anyway, see THIS LINK TUTORIAL that was recently posted and does a pretty good job of explaining it...

It works!

Thanks for teaching an old dog a new trick.

Ed

Duggie7mag wrote:

I just bought a '81 KZ750LTD...

Woot! High 5 to a fellow '81 KZ750LTD owner! At some point I'd like to re-do the wiring on my bike as well so I'll keep an eye on your thread for any tips you may share as you move forward.

I'm holding off for now because my bike has been off the road for too long already. My z1 order arrives Tuesday so I can get back to work. I love all the learning but damn do I miss riding her!