TOPIC:

wrote:

Thanks Wookie ! I'm marking my old harness before I remove it and marking the new harness before install, I did the Wired George mod over 20 years ago but the Batt./white wire supplied in the new harness seems to be 18 gauge where the stock looks like 14 gauge going to a 20 amp main fuse. 

Joe, I hope you don't mind me sharing my pain in your thread but I've been using it to deal with my frustration.

So Moose, I have run the numbers through a cable size calculator (see below) 14 gauge would be fine, 18 gauge is marginal unless you use a by-pass relay to take some of the load off the main circuit. However the thing that most people forget is that the "ground line" needs to be at least the same gauge as the feed (current is like a school field trip - "what goes out has to come back") Given that these bikes seem to run a single ground line (Black/Yellow) if that cable is also marginal I would recommend adding an additional ground line to avoid problems later

 

I noticed the same thing with a new harness. I bought one for my 76 project but after seeing the small gauge wires I decided to clean up my original one. The original is completely intact just not a snappy looking as I’d like. I was hoping to use the aftermarket harness on another future build. 

wrote:

I noticed the same thing with a new harness. I bought one for my 76 project but after seeing the small gauge wires I decided to clean up my original one. The original is completely intact just not a snappy looking as I’d like. I was hoping to use the aftermarket harness on another future build. 

Mikaw, I thought about running a 12 gauge wire solo from the ing. switch to the closest batt. terminal near the battery. 18 gauge main just doesn't get it with me. And Wookie I have added extra grounds.

Well mine is alive and firing on all cylinders. I've done a few starts and heats cycles for the paint on the cases. I had to take the tank off my red bike to fire it as I wait the paint shop with my tank and bodywork. I have video if anyone wants to see... I just did not want to take up space with that. I built a 1976 KZ1000  with a 1075 kit for my brother a few years ago and it needs fork seals and an oil change ... so my garage now looks like a kawasaki dealership. But ... the race gas smells awesome! lol.