78 KZ1000A2 wire routing question

  • testarossa
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29 Sep 2010 07:39 #402673 by testarossa
78 KZ1000A2 wire routing question was created by testarossa
I never had a headlight when I bought my basketcase KZ1000, so I'm not familiar with what wiring is supposed to be hidden inside the bucket. Obviously the headlight and front turn signal wires go in there, but what about the ignition switch harness and the dash light harness? Are those connectors hidden in the bucket or are they just routed under the neck like the rest of the wires?

1978 KZ1000 A2 Click--->Build Thread
2004 ZX-10R
2007 Harley Sportster 1200
2020 Harley Street Glide Special
Angola, IN

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29 Sep 2010 11:51 #402709 by MFolks
Replied by MFolks on topic 78 KZ1000A2 wire routing question
If the wiring has enough length, tuck it inside the housing. This way it's protected more from moisture than being outside.

I've found that ty-wraps will keep the sub harness restained better than anything else.

1982 GPZ1100 B2
General Dynamics/Convair 1983-1993
GLCM BGM-109 Tomahawk, AGM-129A Advanced Cruise Missile (ACM)

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29 Sep 2010 12:18 #402716 by testarossa
Replied by testarossa on topic 78 KZ1000A2 wire routing question
Thanks for the reply Mfolks. My sub harnesses don't quite seem to reach. That's why I ask. However, my front end is decidedly not stock. Although I'm using stock gauges and headlight, they are on new brackets necessitated by my upside down fork swap.

1978 KZ1000 A2 Click--->Build Thread
2004 ZX-10R
2007 Harley Sportster 1200
2020 Harley Street Glide Special
Angola, IN

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29 Sep 2010 13:12 #402721 by MFolks
Replied by MFolks on topic 78 KZ1000A2 wire routing question
Wrapping the connected smaller harness with some good electrical tape will minimize getting moisture inside the connectors.

If it were me, I'd get some "De-Oxit" contact cleaner/preservative from either Radio Shack Stores or an electronic supply place. www.deoxit.com is their website.

Why WD-40 Should Not Be Used On Motorcycle Electrical Items.

For many years, I was proponent of the use of WD-40 on fuse clips, fuses, switches and connectors. After hearing of other peoples experience with intermittent and sporadic activity, I shrugged it off as maybe they did something wrong in the application of the product.

It wasn’t until the time I rode my 1982 GPz1100 B2 model to down town San Diego that I encountered the problems others had gone through.

After concluding my business downtown, I walked to where my bike was parked, turned the key to unlock the forks, and prepared to start the engine. The key was in the “On” position, yet I had no lights in the dash panel, the fuel pump was not running(I have FI), and the horn and tail light were not working.

Stumped as to why nothing electrical was happening, I remember my earlier conversations about how WD-40 will over time become a non-conductor(more like an insulator). I had some pieces of 400 and 600 grit sandpaper in my tool kit and with them was able to scratch away the coating from the WD-40 on the fuses and clips.

After removing the insulating film, the bike started and ran like it should. Since that time, I’ve told people about the problem with WD-40. If you must use a contact cleaner, I recommend getting some “De-oxit” from Radio Shack Stores or any good electronic supply store.

1982 GPZ1100 B2
General Dynamics/Convair 1983-1993
GLCM BGM-109 Tomahawk, AGM-129A Advanced Cruise Missile (ACM)

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29 Sep 2010 13:42 #402725 by seanbarney41
Replied by seanbarney41 on topic 78 KZ1000A2 wire routing question
My kz1000a2 has very little wiring inside the headlight bucket although not sure exactly what right now. Also my bike is a bit of a "bitsa" as well and has had a handle bar swap. All of the switchgear wiring goes to the harness under the tank. I can check it out more thoroughly and attempt a "not necessarily useful photo" with my webcam(only camera available) if no one more knowledgable pipes in.

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29 Sep 2010 19:47 #402787 by testarossa
Replied by testarossa on topic 78 KZ1000A2 wire routing question
Thanks guys. No pictures necessary. I sure wish I knew about that De-oxit when I was individually cleaning connectors with Brasso. Oh well, they're all good and clean. I get the same voltage at the coils as the battery, so I'm good to go. I just wanted to know if those two connectors are supposed to be in the bucket or not.

1978 KZ1000 A2 Click--->Build Thread
2004 ZX-10R
2007 Harley Sportster 1200
2020 Harley Street Glide Special
Angola, IN

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