How much EXTRA wiring is there?

How much extra wiring is there in my KZ750? I like the idea of "minimal wiring" and redoing the whole thing. Here is my dilema. I want most of my "stuff". I want my headlight, tail light, turn signals, horn, idiot lights and gauges along with the charging and necessary stuff. I don't care about my 4-way flashers, but I may use the switch for something else.

So is it worth re-wiring? I already eliminated the clutch switch.

I'm not sure there is any point in doing it.

One reason I want to do this is that I want to change my headlight, but with all the wiring in there, I feel like I need to clean it up.

Yes, if you are keeping most of the electrical, then you'll want to keep the stock harness. If for nothing else, at the least the colors will match the diagram for troubleshooting.

If the bike is having electrical issues and you can get a new harness, that's the way to go. The problem with used harnesses is that they will likely have the same trouble spots since all harnesses wear in the same areas (anywhere the wiring has to move to accomodate chassis movement).

If your old harness is relatively clean, you can spot repair the trouble areas. After you take the harness off, unwrap the areas near the steering to expose all of those wires. Then look at the individual wires. Anywhere the wire appears to have a bump under the insulation is a likely candidate for a broken or weak spot. The conductors will usually break and have a kink at the break. That creates the bump.

Kawasaki, like the other manufacturers uses usually a crimp splice sometimes covered in black tape. Other times it might have heatshrink tubing covering the crimp.

On your wiring diagram, you may notice places where several wires of the same color are joined(spliced together)this may become a trouble spot as moisture will get into the splice causing corrosion if it's not covered with a water resistant protector.


I use the type of splice thats first crimped on the wires conductors, and then shrunk down using a heat gun. This type usually has an inner adhesive that melts sealing the joint from vibration and moisture.

Heat Shrink Butt Splices From Cable Organizers
www.cableorganizers.com
PART # WIRE GAUGE COLOR PACK QTY PRICE
NSPA-KS5-20 22-24 AWG CLEAR 50 $13.89
NSPA-KS5-16 18-20 AWG RED 50 $13.49
NSPA-KS5-14 14-16 AWG BLUE 50 $13.82
NSPA-KS5-10 10-12 AWG YELLOW 50 $16.48


Dry Vinyl Tape From Tape Brothers
www.tapebrothers.com

Dry Vinyl Tapes are non-adhesive plasticized polyvinyl chloride film tape. Easy unwinding characteristics - tape clings firmly to it’s own backing for tight wrap. High elongation and good strength to permit trouble-free binding of wiring harnesses for the automotive industry. Dry vinyl tape also used for plating applications- high stretch, good “cling” characteristics and great conformability provide for superior masking in hard chrome and other plating applications.

DVT-76B 2 in. x 250 ft. Black Dry Vinyl Tape
2 in. x 250 ft. Black Dry Vinyl Tape
Our Price: $6.54 Per Roll

www.wiringharness.com
• Non-Adhesive Vinyl Harness Tape, made to the original mil-thickness.
• Just wrap it tightly around the wires and knot the end.
• 100 foot roll is enough to do 3 to 4 harnesses complete.
• Available in three different widths, as original.
• Correct for all years (1955 to Present).

Part # Description Price
R0058272 3/4" Vinyl Harness Tape, 100 foot roll $12.00
R0058276 1" Vinyl Harness Tape, 100 foot roll $13.00
R0067108 1-1/4" Vinyl Harness Tape, 100 foot roll $15.00


Electrical Contact Cleaner/Preservative
www.caiglabs.com
Insulated ratcheting crimping tool (22-18,16-14,12-10 gauge)
www.amazon.com/0380PT-22-10-Ratchet-Term...imping/dp/B001QRW20W

Electrical Connectors, Wire, And supplies
www.easternbeaver.com
www.vintageconnections.com
www.z1enterprises.com/catalog.aspx?pid=KPEL1
www.vehicle-wiring-products.eu
www.electricalconnection.com
www.electricalconnection.com/electrical-components/hitachi.htm
www.delcity.net
www.digikey.com
www.waytekwire.com
www.alliedelec.com
www.mouser.com
www.terminalsupplyco.com
www.pbase.com/mainecruising/wire_termination&page=1
www.crowbarelectricalparts.com/butt_connectors.htm
www.terminaltown.com
www.electerm.com
www.wiringproducts.com
www.autoelectricsupplies.co.uk
www.painlessperformance.com
www.rallylights.com
www.ironbutt.org/forum/forum_posts.asp?TID=1759&PN=1
www.ratwell.com/technical/Terminals.html
www.economycycle.com/servlet/the-Bullet-...lectrical/Categories
www.surplussales.com/SolderlessTerminals/WireTerminals-3.html
www.findtape.com/shop/product.aspx?id=32...&width=1436&height=0