75' KZ400 Wiring / Kick to Electric Conversion

  • DannyKZ
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07 Jul 2016 14:01 #734178 by DannyKZ
Hey all,
I picked up 2, 75' KZ400's about a month ago and have started tearing into them. One bike has 5k with a kick start only and I got it started (on 1 cylinder), the other one has 8k, an electric start, and is a complete rust-bucket, but has good compression and the electrics all work (including the starter!).

Off the donor bike, I've robbed the starter, chain, solenoid, complete harness, and switch-gear, as well as the dynamo and starter-clutch. The dynamo removal was the hardest part, had to order a special 18mm x 1.50 pitch bolt, because the largest bolt/axle on the KZ is a 16mm.

Anyhoozle...

I want to have as "tidy" an electronics package as possible... and plan on running the following gear on the bike.

- Headlight (hi/lo)
- Speedo only
- Turn/Neutral/Oil/Hi-beam lights
- LED turn signals (will use LED flasher w/built in resistor)
- LED tail light, 300ohm resistor switched dimmer.
- Horn

Everything I have works, as far as switch gear, brake light switches and everything else.

Does anyone have a dumb-down simplistic version of a wiring diagram that will incorporate directionals, a combined R/R, and elimination of the "dummy" tail light warning circuit?

Life's a tour, not a race. Just stay out of my way when I'm touring.

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07 Jul 2016 17:52 #734192 by Nebr_Rex
Replied by Nebr_Rex on topic 75' KZ400 Wiring / Kick to Electric Conversion
Do a search of the www and there will come up a drawing of a simplified wiring diagram.


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2002 ZRX1200R
81 GPz1100
79 KZ1000st daily ride
79 KZ1000mk2 prodject
78 KZ650sr
78 KZ650b
81 KZ750e
80 KZ750ltd
77 KZ400/440 cafe project
76 KZ400/440 Fuel Injected

www.dotheton.com/forum/index.php?topic=39120.0


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08 Jul 2016 04:58 - 08 Jul 2016 04:58 #734223 by martin_csr
Replied by martin_csr on topic 75' KZ400 Wiring / Kick to Electric Conversion
Here's a topic with a bunch of wiring diagrams provided by loudhvx.
1980 750H bare bones for mattylight (pg 1)

For doing the rewiring, if you don't have a ratcheting open barrel crimper, I would get one & use open barrel terminals. the crimps are the same as stock & very strong. cycleterminal.com is where I got most of my wiring stuff when I replaced a voltage regulator. they have connectors & terminal pins that are the same as stock.
Last edit: 08 Jul 2016 04:58 by martin_csr.

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  • DannyKZ
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08 Jul 2016 23:21 #734340 by DannyKZ
Thanks guys! I saw the "hand drawn' one for the KZ400 on here a while back, but it didn't show any blinkers.

Most of those look pretty simple to replicate for the 400.

Life's a tour, not a race. Just stay out of my way when I'm touring.

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