New Baby, Electrical Problem

Picked her up today and she is great. All original for the exception of mirrors, headers/muffler, and fuel petcock. The PO said that he has had issues with the main fues (20A) blowing intermittently. The fuse actually blew on me when I turned the bars fully to the left. I'll dig in to find out which wire is chaffed.

Could someone post a pic or insight on how the harness is supposed to be routed.

Your bike looks great!!! Here's the correct routing:

Welcome.
I had a similar issue, blowing the main fuse, when turning the handle bars.
One of the white plugs in the headlight shell touched the shell edge, and shorted out, as one of the wires/connections in the white plug was sticking out the backside of the white plug and touching the headlight shell.
Check all the wiring.
It looks like yours is looping much lower than mine. Yours even looks to going around the clutch cable.
Try getting more of the wiring into the headlight shell.

Ed's looks to loop lower too on the left side.
Although he's had his 650 since new, so it probably is how they came.

rstnick wrote: Welcome.
I had a similar issue, blowing the main fuse, when turning the handle bars.
One of the white plugs in the headlight shell touched the shell edge, and shorted out, as one of the wires/connections in the white plug was sticking out the backside of the white plug and touching the headlight shell.
Check all the wiring.
It looks like yours is looping much lower than mine. Yours even looks to going around the clutch cable.
Try getting more of the wiring into the headlight shell.

Ed's looks to loop lower too on the left side.
Although he's had his 650 since new, so it probably is how they came.

That pic was taken when I was removing the front forks, so I may have pulled a little on the harness resulting in some extra slack. Here's a pic with everything buttoned. Ed

Thanks all for the photos, exactly what I was looking for. I'll post when I find the culprit.

Well, I found two things. In my bike both sets of harness were routed through the left side instead of one on each side. Had to disconnect all connectors and reroute. I could only find one set of wires that were smashed with the strands exposed. It was the set that went into the front brake light switch. I was looking at the wiring diagram and couldn't figure out how that would blow the man 20A fuse. Nevertheless, it's fixed.

I also need to replace the headlight and it appears to be a common 7" lamp. Couldn't find one at my local shops. It would be nice to find a 7" lamp housing and then use the newer halogen bulbs instead of the old school sealed lamps. Any ideas?

Man, this little bike is a rocket. I forgot how fun they were. I had a 550 ltd back in the day, sold it for a Maxim 750, and then Harleys from there. This little bike seems to pull more from the get go.

I loved the kz650 s r's the red was a real head turner....... neat

If that's the same headlight used on the 900/1000 which it appears to be look for an automotive halogen bulb

Here's the light I use. I'm very happy with it.

www.summitracing.com/parts/WAG-H6024/

Yeah, it looks like a common auto light, but for some reason the parts store only carries 6" and not 7". The one that came with the bike works but it's very dim. I wanted to get something with more candle power.

killer bike...have you tried pushing down a bit or up on then headlight housing...while on a dark slow road at night...it may not be pointed right ...which helps tons on these old things...imo

No eBay APP ID and/or Cert ID defined in Kunena configurationWhat about something like this. Wonder if it's brighter.