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TOPIC: Kz550

Kz550 11 Jan 2019 19:29 #796561

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Hey everyone been a while , was just looking through the factory service manual for my 550 wiring diagram... doing some winter wiring cleanup but the image quality is pretty bad. Third party manual doesn’t include the A4, any suggestions ?

In the meantime, I’ll start deciphering what I can and crosschecking the drawing pictorials with an earlier year since a few of components seem similar.
1983 KZ550- A4
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Last edit: by Mcren.

Kz550 12 Jan 2019 07:30 #796580

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Is the diagram in the manual poor or do you just have a poor copy? And did you scan it or what? Also, is your manual a pdf or hard copy?
The owner's manual for my motorcycle has a small fold-out wiring diagram. As an experiment, I took some photos w my phone & the images are pretty clear after enlarging. If the wiring diagram in the service manual is good, you could do the same. assuming you have the hard copy.




...

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Kz550 12 Jan 2019 11:29 #796597

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That was a direct snapshot I took of the page from manual, The manual I have is the pdf version. I believe the scanned page in it is of poor quality. I’ll try and look around on eBay and see if I can snag a hard copy of it.
1983 KZ550- A4

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Kz550 12 Jan 2019 13:41 #796605

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This won't help you because it's for the Z1 900 model but you might want to copy the idea. I had access to a printer/plotter and made a 3 ft by 5 ft (roughly) copy of the Z1 wiring diagram and put it on my shop wall.
I ride Z1's. I have a couple of '75's, plus an '80 KZ1000LTD. My lovely Sweetums rids a 1981 KZ550.
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Kz550 12 Jan 2019 14:38 #796609

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Yes, unfortunately, the 1983 Kz550 models wiring diagrams seem to only be in black and white. You probably have the same one from my website from the white base manual (1983 covered in the appendices). I attached a partial sample of it blown up a bit. I can barely make out the wire color abbreviations for the more obvious wires. I'm not sure where the scan came from, but I think it's the only one of the white base manual.

Ironically, the 1983 models and later, and maybe some 1982 models, have a new configuration of the main fuse wiring, so their diagrams are arguably more important than other earlier models which all followed the same, earlier conventions for the main fuse. The reg/rec output wire is not fused to the main ignition switch. This means if the main fuse blows (or breaks) for some reason, at higher RPMs on the highway, the bike might not shut off. But the main fuse being broken will disconnect the battery from the rest of the bike's load. In this condition, the bike may continue to run but the regulator will lose the ability to regulate properly. This has been known to happen on other Kz's when the battery became disconnected while on the highway, resulting in melted light bulbs and damaged ignitions and regulators.

That is probably the biggest functional difference. There are likely other minor ones and then of course some changes in wire colors happen too.

If you have questions about specific areas, I can help figure it out if you post the section here, or just describe the area in question.
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Kz550 12 Jan 2019 15:46 #796612

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Some coloured KZ550 wiring diagrams.

1983



1984 USA/Canada



1984 Europa



1985



FSM Chart

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Kz550 12 Jan 2019 17:14 #796625

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loudhvx wrote: Yes, unfortunately, the 1983 Kz550 models wiring diagrams seem to only be in black and white. You probably have the same one from my website from the white base manual (1983 covered in the appendices). I attached a partial sample of it blown up a bit. I can barely make out the wire color abbreviations for the more obvious wires. I'm not sure where the scan came from, but I think it's the only one of the white base manual.

Ironically, the 1983 models and later, and maybe some 1982 models, have a new configuration of the main fuse wiring, so their diagrams are arguably more important than other earlier models which all followed the same, earlier conventions for the main fuse. The reg/rec output wire is not fused to the main ignition switch. This means if the main fuse blows (or breaks) for some reason, at higher RPMs on the highway, the bike might not shut off. But the main fuse being broken will disconnect the battery from the rest of the bike's load. In this condition, the bike may continue to run but the regulator will lose the ability to regulate properly. This has been known to happen on other Kz's when the battery became disconnected while on the highway, resulting in melted light bulbs and damaged ignitions and regulators.

That is probably the biggest functional difference. There are likely other minor ones and then of course some changes in wire colors happen too.

If you have questions about specific areas, I can help figure it out if you post the section here, or just describe the area in question.



Alright, if I have any questions I'll be sure to ask. At this point I'm just confirming a few connections ,re wrapping the wiring and doing a general cleanup of the connections and the previous owners butchery. '


Those scans for the ZX models are worlds better, I'll use what id pertinent and continue my cleanup.

I'll attempt to print on a 11x16 format but I doubt it will help.
1983 KZ550- A4

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Last edit: by Mcren.
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