TOPIC:

Just a heads up with a solution for owners of the 1981 or 1982 KZ1000 LTD with a bad ignition switch. As we all know the original part number for this switch was #27004-5102 which is no longer produced and rarely on Ebay.

My solution which works perfectly in the frame mount and odometer "dashboard" is from the 90's Vulcan 750 which is part number #27005-5052 readily available from Kawasaki or on Ebay as new stock with keys. The only change is the "plug in" connector on the Vulcan switch is smaller than the KZ1000 LTD connector. The color code is the same as well as the 7 wire output and frame locking mechanism.

My original "metal key body" was in perfect condition but had suffered "plastic rot and destruction" of the switching assembly. So you have a choice to use existing keys if you have a viable unit or can replace the entire switch with the new switch. Simply cut off the 6 wire connector from the donor and splice to the matching colors of the new switch.

May sound complicated but a very easy job to perform.

Was it necessary to cut off the donor connector? Couldn't you just use a terminal pin tool & swap the plastic connector? Thanks.

Just an FYI. From the diagrams at Partzilla 27004-5102 is the complete lock set part number >> ignition switch + seat lock + helmet lock.
27005-5019 is the part number for the ignition switch.

You have to splice as the pins are a totally different size. I always solder and heat shrink all splices, easy to do, or you could try to find a matching female plug in the newer design connection at the wire harness I suppose. Thanks for pointing out the part number mistake, at 64 the eyes can play tricks..............

Thanks. I hadn't considered the terminal pin size.

Here is a picture of the completed project.

I know it's an old post but thanks anyway to the original poster!!
I'm precisely looking for such a discontinued switch and having this Vulcan 750 option is GREAT news!
Many thanks for sharing this.

I know this is old, but some problems never get old! I´m searching for a Vulcan 750 ignition switch, but that model was not very popular in Spain, so all I´ve found for the moment is a Vulcan 500 switch. Looks very similar to the 750, but only has 5 contacts in the connector. Please see attached pix. Can someone tell me if this could work? 

Cheers.

Carlos 

If you can find me a wiring diagram for the Vulcan I will be able to tell you if you can use it

This should help!

kzrider.com/forum/4-electrical/617798-19...h-diagnostics#869885

PDF: drive.google.com/file/d/0B23DfMXHXUWiS1J...XDtaXY2E1ayrsyvvFjug

 


EDIT: to the Admins, the PDF file upload failed multiple times!

Thanks Scirocco, do you know if this is the same as the Vulcan 500 he has the switch from ?

give me some time for a search....

Found it. Let me know if this bit is enough. You can see the 5 pin switch connector in the top left. Also the connector pic. 

Thank you!