i really need some help. im new to building motorcycles on my own. im a machinist but this is my first wiring job and first bike that i got that wasnt running yet. i have a 1975 kz400. I need to switch out the ignition (he didnt have the keys, and the toggle switch that is up front goes a couple wires to headlight but there are wires with connectors on them but some were dissconnected and i dont know what to do. i really need help. by the way thisa is kick only bike. please help!!!!!
If I am correct there were 2 different versions of the 400 offered in 75. The D model with electric start and I think a disk front break. The second offered was a S model with not electric start, a drum front brake and a 2 into 1 exhaust. The wiring system is pretty much the same, except for the starter system. Do you have access to wiring diagrams here are ones for the S and one for the D model.
The KZ400.com site has a manual & wiring diagrams (diagrams in the Technical tips section). Warning: do not go into the forums as they may harm your computer. I guess this is still true about the forums. The site didn't have an administrator, hence the problems.
Simplified wiring diagrams: search KZR for Bare Bones for Mattylight >> topic by loudhvx.
Some of them are missing, but there's probably one or two you can use.
also have one more question. i have a different ignition and i dont know what wires go to what pronges? Here are some pics of how it was wired and my new one?
the brown,blue,red,and yellow are hooked to the "A" and the white is hooked on "B" on old ignition. how do i put these on new ignition?
From the pic of the old key switch I am unsure of what the yellow wire is. I can not see it noted on the wiring diagram(s) posted or I have access to. Do you have a volt ohm meter or a test light to see which post does what when you turn the key.
That is someone's custom wiring. You should trace it out or just replace it. If I had to guess, I would assume red was for the tail light, blue is for the headlight, and yellow was to the ignition coil to power the ignition system. But that's a wild-ass guess and would need to be verified with a continuity test.
The way it was previously wired, the red, yellow, and blue all go to one terminal so they would on the new switch as well. Put those three wires on the terminal marked IGN. The other wire you have would go to the BATT terminal.
If on the old switch, you have a white wire and a brown wire going to the same terminal (I can't tell by the photo), and the wire colors are the same as a stock bike, that would be a wiring error. White is usually un-switched 12v and brown is usually switched 12v. They should not just be hardwired together unless other changes were done.
Also, as a side note: Those aftermarket ignitions like that in the first photo, tend to be unreliable. Vibration seems to make them come apart in a short time. Just keep an eye on it.