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Z1 Color Wiring Diagram? 17 Jun 2021 18:57 #850335

  • Mikaw
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The PO has the alternator wired directly to the RR instead of going through the panel with the blue and green connectors. Does anyone see any advantage or disadvantage to doing it this way?
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Z1 Color Wiring Diagram? 18 Jun 2021 05:36 #850350

  • slmjim+Z1BEBE
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The PO has the alternator wired directly to the RR instead of going through the panel with the blue and green connectors. Does anyone see any advantage or disadvantage to doing it this way?
Advantage:
Expediency.  Those old OEM pin connector pins are very uncommon & difficult to source unused, and require a very good crimp tool to install correctly that most enthusiasts won't have anyway.
Bypasses a few pin connectors that are at the ragged edge of current capacity.
Eliminates a common location of corrosion where male & female pin connectors mate.
If done right, the crimps connecting the wiring are very sound mechanically and, electrically can at least match the current-carrying capacity of the conductors to which they're attached.

Disadvantage:
Makes disassembly more complicated if butt connectors are used, necessitating cutting the conductors.
Can be time consuming to make a clean-looking installation.
Documentation of the modified wiring diagram is seldom done, resulting in mystery circuits that have to be identified & explored by future owners.
Color codes seldom match.
Often require hacking an OEM wiring harness in ways that are not reversible.

There may be more, but that's just off the top of our heads.

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Z1 Color Wiring Diagram? 18 Jun 2021 10:16 #850366

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That's right.  It's a universal RR.  I don't want anything to be hokey on this bike.  I read an article that wiring the RR directly to the 3 dynamo phases is a cleaner install in that the more connectors you can eliminate, the less potential problems.  Which makes sense. Wiring it direct eliminates the blue, green and white connectors on the panel.  And thanks SlimJim. All good points to consider. 
KZ900; Z1

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Z1 Color Wiring Diagram? 18 Jun 2021 13:17 #850370

  • hardrockminer
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Just remember to wire your neutral switch and your oil pressure switch because those are wired through the blue plug.
I have several restored bikes along with a 2006 Goldwing with a sidecar. My wife has a 2019 Suzuki DR 650 for on and off road.
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Z1 Color Wiring Diagram? 18 Jun 2021 15:49 #850381

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I read an article that wiring the RR directly to the 3 dynamo phases is a cleaner install in that the more connectors you can eliminate, the less potential problems.

If you wanted you could get rid of all the connectors in the headlight, all the connectors under right side cover, all the tail light connectors, that would be cleaner, lots less problems.
The factory used connectors so parts could be easily replaced.
Oil pressure switch blue wire
Neutral switch green wire

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Z1 Color Wiring Diagram? 24 Jun 2021 18:28 #850719

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I've been slowly working my way through the wiring.  I have most of the easy stuff connected, turn sigs, brake lites, head light, coils.  I've gotten down to the RR which has me stumped on what to do.  As I previously mentioned, the PO wired the stator directly into the RR, which is simple enough but what I'm concerned with is, this eliminated the blue, green and white connectors from the panel.  So I'm wondering what from the brown plug, if anything, is dead ending in the white, green and blue female connectors?  I think someone mentioned that connecting the RR this way requires a couple splices into the harness. If that's the case, I'd rather go back to running everything through the blue, green and brown connectors the way it was stock (minus the white which gets eliminated with an RR).  So anyone know if there's any splicing required when wiring stator direct to RR; and if so, does anyone know where replacement male green and blue connectors could be acquired?  Also someone mentioned that connecting the wires to replacement connectors is very hard without some special expensive tool. Any recommendations on that?  Thanks to all of you for your help so far.  I'm no electrical wiz to start with and this PO has run different color wires (Neutral wire I just figured out is now purple) and this work he did on the RR is the biggest challenge.  But slowly I'm getting there.  Almost ready to hook up a battery and start testing.
KZ900; Z1

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Z1 Color Wiring Diagram? 24 Jun 2021 19:46 #850721

  • hardrockminer
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If it was me I would bring that bike back to stock wiring.  You can buy the female side of the  wiring plugs from Doremi USA, with the correct colours.
But I don't know anyone who sells the male plugs in the correct colours except for the main harness (brown) plug.  Green is the voltage regulator, and you would get one if you bought a used regulator.  White is the rectifier and again, you would get one if you bought a used rectifier.  Same for the blue one on the stator.
 
www.doremi-usa.com/lights_electrical_c37/

The special tool and proper connectors can be purchased here.  www.vintageconnections.com/

 
I have several restored bikes along with a 2006 Goldwing with a sidecar. My wife has a 2019 Suzuki DR 650 for on and off road.
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Z1 Color Wiring Diagram? 24 Jun 2021 20:24 #850723

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Thanks Hardrockminer.  I just found this old post of Steve West's....  Steve, this is a Godsend.  Exactly what I was trying to figure out.
KZ900; Z1
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Z1 Color Wiring Diagram? 29 Jun 2021 15:48 #850914

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Wiring Done!!!  All checked out except starter (cams still off) and coils.  Thanks to everyone for your schematics and advice.  Next up...  reinstall cams and timing chain.
KZ900; Z1

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