Headlight wiring feeds

Does anyone have any suggestions as to the proper installation of the wiring harness as it feeds the headlight bucket? The issue I see is the excessive flexing of the covered harness where it enters the headlight bucket when you turn the wheel. Do I just feed the covered wires inside or strip back the harness covering and just feed the wires? It just seems like there is way to much stretching and pulling going on with the whole cable bundle feeding through.

You posted this request for help three times; hopefully one of the mods can delete the dupes. If you are on a slow dial up, have patience once you hit the "send" button... I have been guilty of this myself a bunch of times thinking nothing is happening.

Now on to your issue. There are TWO wires coming off the hi/lo beam switch that feed your headlight. One is a red/black wire and the other a red/yellow. These wires plug into a mini-harness along with a ground that comes off the main harness. This mini harness has a large round black 3 pin plug that plugs into your headlight bulb holder.

I would not run the red/black and red/yellow wires into the headlight shell without first wrapping them securely in tape to avoid chafing the wire insulation. If it chafes, you run the risk of a short developing.

Thanks George. I only clicked on the submit 1 time. I have no idea how the heck it posted multiple times. Thanks

Just a thought... if the large access hole into the headlight bucket has no rubber grommet its a good idea to add one. It will help protect the taped wires.
My KZ650-B1 was originally equipped with one but was lost by the one of the previous owners. So I had to add one, but I don't remember if I got it from a dealer or Z1 Enterprises.

You can check if your bike was originally equipped with on at BikeBandit as follows:
www.bikebandit.com/partsbandit/oem-nav.a...el_dept_mfr=Kawasaki

Best of success!

Post edited by: bill_wilcox100, at: 2007/07/31 13:53

I believe you'll find the headlight grommet part number is 92071-1008. Ed