Kawasaki Z1000 K1 LTD Ignition Switch Replacement

Hi

I had an issue with the ignition switch on my LTD - basically it started jamming so it couldn't be turned with the key without considerable force.  I managed to source a replacement which has the exact same dimensions as the original, so it fits in the top yoke, but the wiring colours are different - it's for a Kawasaki Vulcan 750.  Z-Power sell these switches but they don't know what wires I need to connect to make it work properly.
On the original Z1000 switch I have 6 wires in the multi block connector (black/white, orange/white, brown, red, white, orange) and a yellow/orange bullet connector. 
On the vulcan 750 switch I have 5 wires in the multi block (blue, yellow, orange/white, red, black/white) and 2 bullet connectors - one white and one brown/white. 
The multi block on the Vulcan 750 switch is a completely different size so I cut it off and replaced the connectors with 6.3mm ones. 
I've connected the wires from the new switch to the multi block in the headlight in a variety of positions and the best scenario I can get is , power to starter, lights, indicators - no oil light or neutral lights. Brake lights only work when the lights are switched on.
I've read a few form posts on this subject but there aren't any conclusive answers from what I can see.
If anyone is  able to shed any light on to which colours on the new switch connect to which colours on the Z1000 multi block  in the headlight I’d be much obliged as I'm no wiring expert and even less of an expert on reading wiring diagrams

thanks

Billy

You have a couple of options, it appears that your problem is mechanical so below is a link to a tutorial I wrote on how the repair the ignition lock.

82 J,K &M ign barrel removal - KZRider Forum - KZRider, KZ, Z1 & Z Motorcycle Enthusiast's Forum

If you want to fit the new unit complete below is how (I believe you could have just swopped the original electrical switch onto the new lock)

Thank you @Wookie58  I'll have a read through your tutorial but I think that would be my last resort. Plugging the new switch in is the ideal solution so I'll check the colours of new against old and see where i get to.
Thanks for your quick response.

 

Have you taken the stock switch apart, cleaned and reassembled with fresh dielectric grease?
Many times the original grease is hardened and causes issues.

@Kelly E - haven't taken anything apart yet  - that's a last resort.

@Wookie58  Managed to get into the garage to try this and connected everything up as per your table. However........I have a blue wire on the vulcan switch going to N/A ?  And a brown wire on the bike receiving nothing N/A ?  So without those two wires connected to anything everything works except oil light, neutral and brake lights. Oil light now flashes in time with the indicators and the brake lights work only when the lights are switched on.  I tried connecting the blue wire on the new switch to the brown wire on the multi block and nothing works except the oil light 
I'm wondering if it might be simpler to swap the black electrical socket from the old switch onto the new one so I have the new barrel and the existing wiring connectors. Do you know what's involved in removing that ? Does that involve drilling as detailed in your procedure ?

many thanks

Billy

 

Zoso wrote:

@Wookie58  Managed to get into the garage to try this and connected everything up as per your table. However........I have a blue wire on the vulcan switch going to N/A ?  And a brown wire on the bike receiving nothing N/A ?  So without those two wires connected to anything everything works except oil light, neutral and brake lights. Oil light now flashes in time with the indicators and the brake lights work only when the lights are switched on.  I tried connecting the blue wire on the new switch to the brown wire on the multi block and nothing works except the oil light 

I'm wondering if it might be simpler to swap the black electrical socket from the old switch onto the new one so I have the new barrel and the existing wiring connectors. Do you know what's involved in removing that ? Does that involve drilling as detailed in your procedure ?

many thanks

Billy




 

One cross head screw and a clip The ZN diagram I have isn't factory so maybe a few small anomalies
PS: is your bike Euro or US spec (does your right handlebar switch have a "PO" & "ON" positions for the lights ?)

@Wookie58I'll have look at removing it then as it could potentially be simpler than the wiring colour match 
Yes I believe it's a UK spec bike. The right hand switch has the newer rocker light switch  - same as the GPZ.

 

Found some time to try and get this sorted out. I removed the electrical switch from the old ignition barrel and attached it to the new Vulcan barrel ( 5 minute job ) but that solved nothing as although all the lights, indicators etc worked (except neutral but that could be a different problem) the bike won't start - nothing when you press the starter. Changed the right hand switchgear - still nothing.  
So the new Vulcan 750 switch works (to a degree) and starts the bike.  The old switch attached to the Vulcan barrel doesn't power the starter motor. If anybody has any suggestions as to what's going on there let me know please as it's not following any logic that I can see 

Will try and make some time to look at it over the coming days