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Author: Subject: Brake light failure sensor KZ650 and others
OnkelB
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[*] posted on 30-12-2003 at 10:12
Brake light failure sensor KZ650 and others



What excactly is a "Switch, Outage, Indictr" and what does it do?

Itīs connected to the big 9-pin plug in the headlight (going to the dash) and the front brake light switch so I suspect itīs an error alert for the brake lights, correct?

The pic shows the part and where it is situated on the left side of the battery case. Itīs a molded unit and as you can see all the wires are broken off, so Iīm looking for a replacement.

Iīm not concerned with originality, so any tips on cheap auto parts are most welcome.

Iīm currently trying to sort out the mess made by whoever "modified" the wiring (always thought that implied improving).
To give you an idea about what Iīm up against, the bottom pic shows my "fuse box".

[Edited on 30-12-2003 by OnkelB]

[Edited on 31-12-2003 by OnkelB]

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77/78 KZ650 B1
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ibsen22000
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[*] posted on 30-12-2003 at 10:21


It is a brake light failure unit.
It is connected to the stop lamp indicator in the tachometer, and to the stop lamp and the brake light switches.
Both the Kz400 and the Kz900 have got it.

[Edited on 30-12-2003 by ibsen22000]




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OnkelB
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[*] posted on 30-12-2003 at 10:58


Thanks Ibsen, thatīs what itīs called in the Clymer wiring diagram too, doh.

Ok, now I know what to ask for.




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biodello
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[*] posted on 30-12-2003 at 10:59
650



I think my 650 has i too. You could try soldering wires to the terminals.

[EDIT]
You could also buy the connectors at www.digikey.com and remake your wiring harness.

[Edited on 30-12-2003 by biodello]




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OnkelB
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[*] posted on 30-12-2003 at 11:08


Bio, the problem is the wires are broken inside the mold so soldering is not possible.

I am already rebuilding the harness, I get my wires and connectors from a local auto electro shop at a very good price too - Iīll post some before and after pics later.




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[*] posted on 30-12-2003 at 14:33


The problem with the brake failure unit is that it is a closed unit. I do think you can use the unit from both the KZ400 and the KZ900.
I replaced the one on my 400 with one from a 650.




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cool.gif posted on 30-12-2003 at 18:37


Not real familiar with the part, but I'm picturing some kind of epoxy-backed unit ??
If it's toast already, go ahead and tear into it- you can't break it any worse. And you might learn a trick to share ??




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OnkelB
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[*] posted on 30-12-2003 at 23:39


Hey Smokey, thanks for waking me up, donīt know what I was thinking - of course I should take it apart..

The whole unit has been dipped in some sort of rubbery compound - after about an hour of archeology this is what I found: A small electronic circuit consisting of 2 condensers, 2 transistors and a resistor. The condenser closest to the wires is 25V/22uF, the other is 16V/100uF, the transistor you can see in the bottom pic is marked C1384/R 71, the one behind it is marked A733/01 71 and the resistor is 100 Ohms 5% tolerance (brown, black, brown, gold). Donīt know if this info is important to anyone, but there it is.

First pic shows what I peeled off (no, I didnīt try to smoke it, thank you very much).

Second pic shows the bottom of the circuit and the third shows a side view.

The good part is that once I find out where the wires connect I can solder them back on and fabricate some sort of housing. Anyone know the price of this unit btw - did I just waste 1 hour of my life to save 5 bucks?

Note: Title of the thread edited for search purposes.

[Edited on 31-12-2003 by OnkelB]

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[*] posted on 31-12-2003 at 00:46


No, that was not a waist of time OnkelB. You just spendt 1 hour doing something I had intented to to for a long time but never got to do. And I am sure there are more members that will find it useful.Thanks.
Yes that informaton about the parts inside the unit will be useful. I will try to repair the unit I have replaced.
I will open mine, and since the wires still are attached to it , I will post a drawing so you can see where the different cables should be soldered to the curcuit card.
I will take a look at it to morrow.




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[*] posted on 31-12-2003 at 02:01


Bad news OnkelB, I had a look at the unit I had replaced. It is different. There are 4 resistores, 1 condenser, 2 diodes and 2 transistors, and the wires are not attached to the card as on your unit, one is soldered to the card in one corner. and the others in the middle of the card.
Sorry I could not help you on that one.
BTW, the unit was filled with a stuff that was glass hard, so I had to use a hammer on it:o. I don't think anyone can repair it anymore.;)

I bought the used replacement unit from a breaker 5 years ago, and payed Nok 100. Approx $15.




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[*] posted on 31-12-2003 at 06:51
heh nice



Looks like a BJT on there, but anyways at least I will know how to make another one if I kill mine.



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OnkelB
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[*] posted on 2-1-2004 at 02:55


Could one of you 650 guys help me out here?

Thereīs 3 wires attached to this unit: a black, a green/white and a yellow. Since theyīre all broken off, all Iīm really sure about is that the green/white goes in the middle.

Since color coding may vary I found another way to determine where the wires go: The plug on the unit has a notch on one side (pic 1). What I need to know is this: When looking at the unit with the side where the wires attach pointing up (pic 2), to which side is the notch pointing?

The bike in question is a 78 KZ650 B, so if any of you with similar bikes could be bothered to check this for me it will be greatly appreciated.

The unit is located behind the left side cover, right next to the starter solenoid.

Oh, and thanks for your input so far.

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[*] posted on 7-1-2004 at 15:46


On all three of my sense units, the yellow wire goes with the notch. (Green is center as you said).
I'm including a photo of one which shows the wire attachment to the unit. Hopefully the units are all the same as far as wire code.

Evidently (I'm new to the forum) you can click on the photo to see it full size.

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Lou D.
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thumbup.gif posted on 7-1-2004 at 15:50


Yeah, the wires are the same - thanks a lot, you really helped me out here, appreciate it. :)



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[*] posted on 7-1-2004 at 15:56


Glad I could help.

Later,
Lou




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