How are the wires laid inside the headlight?

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13 Mar 2018 21:23 #780197 by Shdwdrgn
I have an 81 KZ1000, but I imagine most models have similar layouts. Now that I have all the wires back inside the headlight can I'm trying to figure out how to make enough room to allow the bulb to fit back in there too. Would anyone happen to have a pic or maybe a description of how the wires and various connectors are arranged? I don't seem to have enough room to lay most of them around the top or even much to the sides so I can't quite seem to get the bulb to sit back in place again.

1981 KZ1000-JK1
She's a beautiful mess, and I've made her all mine

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  • Scirocco
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13 Mar 2018 22:27 #780199 by Scirocco
Replied by Scirocco on topic How are the wires laid inside the headlight?
Some pics inside the headlight




Michael
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14 Mar 2018 06:13 #780213 by davido
I just tried to have the wires as untangled as possible to avoid taking up too much space, then spread them out as best I could to avoid 'lumps'. It was a bit of a squeeze but everything fitted together ok.

www.kzrider.com/forum/11-projects/594313-csr1000-project-build
CB550 (1978)
CB500/4 (1972)*
KZ1000CSR (1981)
XT 600E (1999)
TDM900 (2003)

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14 Mar 2018 08:35 #780228 by Shdwdrgn
Replied by Shdwdrgn on topic How are the wires laid inside the headlight?
Thanks for the info... Seems like I even have the right wires going into the right holes but I had to really work it to get the light assembly to sit back flush to the housing and after I got all the screws in place noticed that the headlight is turned off to one side. I'm pretty sure there should be enough free space for the light to be put back in without any effort so I'll pull it back apart today and try again.

And here I thought threading the wiring harness back through the frame was going to be the hard part...

1981 KZ1000-JK1
She's a beautiful mess, and I've made her all mine

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