wiring my 77 kz 650 cafe what is the best way?

First bike from start so please be kind lol.
1981 kz750 frame
1977 kz650 motor

mistake 1. I removed the wiring harness and snipped off all the ends to re-use only the ones I was going to need.

mistake 2. I rewired it according to the 1981 kz650 wiring schematic

mistake 3. burnt wires up.

lol

so I got to looking and the rectifier has way to many wires compared to the 77 schematic.

there is three yellow wires and a green wire with a red line coming from the alternator

the rectifier has 3 yellow a black a brown and a white with red line do these go to the same bike?

#1. what do I do? Is the 77 a single phase and how do I tell if it has already been switched or not?

#2. am I better off reliable wise to by a 3 phase if so how do I switch from 1 to 3.

I have a 1978 kz650 I could use parts from if it will help I don't know,

thank you so much.

If the 1977 KZ650 motor has the 3 allen bolts on the dynamo cover (see pic) it is the original 3-phase excited field unit.



If that is true, here is the wiring diagram for that bike:
diagrams.kz650.info/wiring/images/KZ650-C1.jpg

Ed

It has no holes on the front at all.
So it is the single phase then.
now do should I stay with whats on it and find the right rectifier
or do should I switch to 3 phase
can I use whats in my 78 kz650
or buy dyna s
thanks for any help and thank you 650ed

It may be a single phase or a later 3-phase generator. The later 3-phase generators were not the excited field type and did not have the 3 allen screws. Take a look at the generator wire colors/configurations in the various wiring diagrams at the link below and you should be able to find a match to your generator.

diagrams.kz650.info/wiring/WiringDiagrams.htm

Also, check you motor's serial number (it's next to the oil filler cap) against the info in the following link to make sure it really is a 1977 unit. It may be a later motor. Ed

models.kz650.info/index.htm

my rectifier pictured matches the 81 kz750 schematic (which is the bike frame) it also matches the kz650d4, h1, and h2. but none of those schematics match the wires coming from my generator. the only schematic that matches my wires from generator is the kz650c1 my motor is kz650be017161.

I have a 78 motor? it was hard to understand the vin look up on this one, numbers on motor are kz650be0703468. that has only 3 wires coming from the generator.

trying to get the 77 running but cant figure out next step do I remove and start over with new dyna s, or can I use parts from the 78 motor or just find the correct rectifier for my 77, what do you suggest?

If your 1977 motor doesn't have the 3 allen bolts in the generator cover it does not have the 1977 generator. Those bolts hold the field coil in place.

It appears that a previous owner has fiddled with the wiring. Your picture shows 3 yellow and one green/red wire bundled together. I believe that green/red wire has nothing to do with your generator; I believe it is the wire from your neutral switch. Take a look under the clutch cover find the source of the green/red wire.

I wonder if the previous owner moved the generator from the KZ750 to your motor? Ed

so if this is the 3 phase from the 81 750 motor then my wiring should of been right, why did it burn all the black/yellow wires?

shit! lol

thank you ED

The red/green wire is for the neutral switch as can be seen in the pic (that's a good thing, the PO didn't do anything odd there).

The stator in the pic appears to be the later 3-phase type. That same piece was used on a bunch of models including the KZ750 (see list below), so the PO may have swapped it from a KZ750 motor. The black/yellow wires are ground, so it's possible the bike had a short circuit that burned them out. That could have been the result of worn insulation on a wire or a faulty electrical component (or possibly the PO wired something wrong - after all, he did change the generator, so maybe he made a mistake someplace in his wiring). You may be able to find the short using an ohm meter and the wiring diagram. Ed

KZ650-H1 (CSR) (1981)
KZ650-H2 (CSR) (1982)
KZ650-H3 (CSR) (1983)
KZ700-A1 (1984)
KZ750-E1 (1980)
KZ750-E2 (1981)
KZ750-E3 (1982)
KZ750-F1 (LTD Shaft) (1983)
KZ750-H1 (LTD) (1980)
KZ750-H2 (LTD) (1981)
KZ750-H3 (LTD) (1982)
KZ750-H4 (LTD) (1983)
KZ750-L3 (1983)
KZ750-N1 (Spectre) (1982)
KZ750-N2 (Spectre) (1983)
KZ750-R1 (GPz) (1982)
ZX750-A1 (GPz 750) (1983)
ZX750-A2 (GPz 750) (1984)
ZX750-A3 (GPz 750) (1985)

is this 3 phase the better system?

should I leave it or put back the single phase?

you've been a great bit of help ED.

If the engine is a '77 it originally had a 3-phase system that is different than the 3-phase system now on it. Some later model KZ650's came with a single phase system, but that was later dropped in favor of a different 3-phase system (which I think your bike now has). Assuming you can get the present system working well I doubt it would be worth the effort to switch to the original 1977 3-phase system or the single phase system as I don't think any of the systems offer a major advantage over the others. Ed