Wiring harness and charging issues 78kz650

Hey guys totally new to this community. I searched around a little but could not fund exactly what i was looking for. So heres my predicament.

Im working with a 78kz650 (i believe its the b). Had it for about two years now but finally got it on the road last summer. I gave it to a friend for a bit who was an autobody guy and a mechanic to paint the tank and mess around with it a bit. He got it up and running for me but we took off the turn signals on the front and back, and wired a small tail/break light replacing the original. Once i started riding around i realized the battery was not charging. So i havent been able to right at night, or during the day for more than a good hour or so.

The guy i bought the bike from never said anyting about electrical problems(although the wiring was already cut up before we took off the turn signals) and was pretty honest about what else was wrong with it. I replaced the rectifier since it was cheaper than the magneto/stator first to see if that was it. I also tried following a wiring problem solving chart to see if i could locate the problem but got totally lost.

Soooo my question is this, the bike is in great shape engine wise and id hate to quick fix this problem and really not mend the wiring system fully. Would you recommend just starting from scratch and making a solid custom wiring harness? I dont need much thr bike is real simple. Head light and brake light. Is this complicated? (Im pretty handy and capable just not the most knowledgable about where to start). Are there harness kits i cant buy and install, replacing the existing one?

Sorry for the long post just wanted to give you guys the back story. Any advice helps

What kind of alternator do you have? Three yellow wires or one? Do you have a manual?
Steve

Which alternator cover is like yours:

1977


1978


1979

Here's a basic wiring diagram:

Another by OMR:

If his bike is a 1978 KZ650 those diagrams don't match his requirements because his charging system is different and has a different number of wires coming from the alternator. Ed

See:
diagrams.kz650.info/wiring/images/KZ650-B2,C2.jpg

The 78

In that case your charging system is the single phase type shown in diagrams.kz650.info/wiring/images/KZ650-B2,C2.jpg and the rectifier is integrated into the regulator.

You stated you replaced the "rectifier." Do you mean you replaced the regulator that contains the integrated rectifier, or did you install a stand-alone rectifier? Ed

I was afraid that would be the case.
Steve

Hello all, mid-project on my first retro/resto...

So I've been trying to piece together information from a handful of KZR threads pertaining to charging systems for the '78 KZ650's... my goal being to get a comprehensive setup utilizing a Shorai Li battery, and a Dyna S electronic ignition (new coils too).

Here's my train of thought so far: it appears likely the Dyna S could potentially overload the single phase charging system of the 650-B2 making it best to convert to a 3-phase system (i.e. new stator and reg/rec). On that note, (1) it's seemingly difficult to get my hands on a new SH775 R/R so any recommended sources for a SH775? Or if not that, what's the next best option e.g. the FH020? And (2), anyone know of a 3-phase stator that would bolt on, perhaps off a 650-D4 or H1?

With regards to the battery: It'll be a kickstart-only so is it possible and reasonable to use a 7 AH, 107 CCA battery versus the more expensive 14AH/210CCA? No quite sure what other impacts the lower Amp rating may have..

Lastly the ignition coils: safe to say the Dyna 3 Ohm would be the proper selection?

Personally, I'd prefer to plan ahead, confident that everything will be compatible and functional than trying to piece things together individually, test, troubleshoot, etc. trial-and-error style. Then again, part of me's tempted to wing-it and hope the stock single-phase system can keep up...

Thanks for any input!

You should start your own thread on this subject.
Steve

Will do. Thanks for the advice.