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1978 KZ200 Headlight and coil 13 Jun 2020 21:14 #828117

  • map747
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I just got a 1978 KZ200. Every light bulb was burnt out and the coil didn't pass the test with the ohm meter. No spark. Where can you get a replacement headlight and coil for the best price? I did find a loose wire (brown) in the loom. Not sure what caused the lights to burn out, maybe a bad rectifier/regulator?

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1978 KZ200 Headlight and coil 14 Jun 2020 06:22 #828136

  • TexasKZ
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Here is a good source of parts

www.z1enterprises.com/motorcycles/Kawasa...lectrical-parts.html

That brown wire may be hugely important. It could be the sense wire for the regulator. If it came loose or was not hooked up for some reason, the regulator would sense no power in the electrical system, and would run wide open, frying lots of stuff. You need a factory service manual with a good wiring schematic, and a decent volt/Ohm meter.
1982 KZ1000 LTD parts donor
1981 KZ1000 LTD awaiting resurrection
2000 ZRX1100 not ridden enough

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1978 KZ200 Headlight and coil 14 Jun 2020 09:52 #828153

  • martin_csr
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Where is the loose brown wire? And does the voltage regulator have a brown wire?
Asking because I'm not seeing any brown wires in the wiring diagram.
Also, how many wires does the reg-rec have & what color are they?

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Last edit: by martin_csr.

1978 KZ200 Headlight and coil 14 Jun 2020 11:20 #828157

  • map747
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The bike came with the owners manual which had this wiring diagram. Before I found the loose brown wire, I did not have power to 2 of the 3 fuse circuits. The white wired fuse did have power,but after I reconnected the brown wire, I had power to the other 2 legs of the fuse box. I do think there was a big power surge as every electrical component was fried. Does anyone know of a source for these headlight? It looks like they silicone a 2C1 headlight into their frame. I guess I could reverse engineer this unless their is a source. OEM parts warehouses don't have it. Also, what do you guys suggest for the replacement coil?
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1978 KZ200 Headlight and coil 15 Jun 2020 10:00 #828248

  • map747
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Did you get a chance to see my recent reply? The brown wire went to the ignition and other places. I believe once I reconnected, I fixed one problem, but the coil was shot. I hope the stator and R/R are still good. The rest of the bike is in great shape.

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1978 KZ200 Headlight and coil 15 Jun 2020 10:03 #828249

  • map747
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Also, I used the frame from the old headlight and planted a H5006 into it. I had to dissolve the silicone that was holding it in the frame. It should work fine. I couldn't find a source for a replacement.

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1978 KZ200 Headlight and coil 16 Jun 2020 09:22 #828290

  • Peter uk
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Hello Map 747
The Z200 come with two types of regulator / rectifier, one with four wires and one with five wires.
the one with five wires has a Brown wire which is attached to the wiring loom.
Have attached a pic of wiring loom. hope this helps.

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