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Replacing stock bars with what? 20 Dec 2014 07:00 #656500

  • Britome
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So I got myself in a pickle. I am trying to bury the wires in the stock bars. When I alligator clip all the ends together, the hazards don't work nor the starter nor the headlight. Help!

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Last edit: by Britome.

Re:Replacing stock bars with what? 20 Dec 2014 07:12 #656503

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Scratch that. The starter works since. Forgot to pull in the clutch. Hazards and light?

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Electrical problem post burying wires 20 Dec 2014 07:18 #656506

  • Britome
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I'm a noob trying to restore a bike that hasn't run for years.

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Electrical problem post burying wires 20 Dec 2014 08:50 #656512

  • 650ed
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Did all the lights test ok before re-routing the wires? Ed
1977 KZ650-C1 Original Owner - Stock (with additional invisible FIAMM horn)

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Electrical problem post burying wires 20 Dec 2014 09:15 #656518

  • MFolks
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I think, one or more metal "Burrs", have stripped the insulation from some wires, causing an electrical short.

Read this:
Pulling Wire Bundles Inside Handlebars

Before running any wiring inside the new bars, take time to see if any sharp "Burrs" are there, otherwise they will quickly strip any insulation away from the wire's conductors, resulting in an electrical short.

A Dremel tool with a small stone grinding bit will smooth most burrs away. If a Dremel is not available, a small round rat tail file works just as good.

Any electrical wire splices, should be “Staggered” to avoid a lump, so the bundle will pull smoothly through the handlebar(s).

When preparing to pull the wire bundle through the bars, carefully taper the bundles end with masking tape as this makes for a better pulling situation.

I use aircraft 0.032" diameter safety wire secured to the wire bundle as a pulling medium, Nylon string or small diameter cord will work for this too.

Silicone spray or electricians pulling lubricant should be applied to the end of the wires to ease the operation. It's best to have a helper while doing this to avoid problems of possible pinched or damaged wires. Have your helper apply a steady pulling effort while you carefully feed the wire bundle into the handlebars.

After the job of pulling is done, get a multimeter, set it on the lowest ohm setting, open up the switch housings to access the wire ends and then see if a wire of two has shorted out.

Put one probe on the handlebar and the other on any soldered wire ends on the switches and see if the meter indicates continuity by either making a buzz(some meters have built in buzzers) or a display on the meter face.

An analog meter(the type with the needle indicator) will act similar (except no buzzer) by showing usually a full deflection(needle movement)if there is a short by again, checking with the lowest setting on the ohm scale of the meter.

Finding a short now is a whole lot better than when it's wired up & blowing fuses or possible stranding you on the road.....
1982 GPZ1100 B2
General Dynamics/Convair 1983-1993
GLCM BGM-109 Tomahawk, AGM-129A Advanced Cruise Missile (ACM)

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Re:Replacing stock bars with what? 20 Dec 2014 11:03 #656529

  • bluezbike
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You may have introduced a short when you pulled the cables back into the bars......pull them back out, make sure of all connections etc, make sure they work while out of the bars, check that the hole has no burrs that could peel insulation off the cables and try again.......also (if not already done) make sure battery has a full charge.....good luck
79 KZ 1000 LTD
77 KZ 1000 B1 LTD (awaiting electrical resurrection)

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Re:Electrical problem post burying wires 20 Dec 2014 11:07 #656534

  • Britome
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Lights were working ahead of time. Very helpful. Thx. I'll try the multimeter.

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Re:Replacing stock bars with what? 20 Dec 2014 11:08 #656535

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Thx. Battery does have a full charge. I'll pull back out and check.

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Replacing stock bars with what? 20 Dec 2014 11:09 #656536

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When I removed the stock internal wiring from the bars on a 78' B2, the wires were wrapped in tape/plastic... within the bars! This just makes sense!

Britome, you need to wrap those wires before putting them thru the bars. Also, as was mentioned... check for burrs on the inside of the holes you opened for this project.
C.
79' KZ650-D2 [fsm] (Max)
83' KZ750-F1 LTD [clymers] (Kay)
82' KZ1100-D1 Specter (another project)
78' KZ650-B2a (J&H, A Project)
91' KZ1000-P (P = parts)

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Electrical problem post burying wires 20 Dec 2014 11:13 #656538

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Why do we have 2 threads for one problem? Can a Mod/Admin consider combining them? Thanks...

kzrider.com/forum/5-chassis/596730-repla...stock-bars-with-what
kzrider.com/forum/4-electrical/596751-el...m-post-burying-wires
C.
79' KZ650-D2 [fsm] (Max)
83' KZ750-F1 LTD [clymers] (Kay)
82' KZ1100-D1 Specter (another project)
78' KZ650-B2a (J&H, A Project)
91' KZ1000-P (P = parts)

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Re:Electrical problem post burying wires 20 Dec 2014 12:59 #656544

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!Seymore wrote: Why do we have 2 threads for one problem? Can a Mod/Admin consider combining them? Thanks...

kzrider.com/forum/5-chassis/596730-repla...stock-bars-with-what
kzrider.com/forum/4-electrical/596751-el...m-post-burying-wires


Good call. I was just concerned that some wouldn't see this post in an initial thread that was a non electrical related question.

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Re:Electrical problem post burying wires 20 Dec 2014 18:43 #656578

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No worries... just pointing it out to the MODs. If they want, it will happen. If not, well...
C.
79' KZ650-D2 [fsm] (Max)
83' KZ750-F1 LTD [clymers] (Kay)
82' KZ1100-D1 Specter (another project)
78' KZ650-B2a (J&H, A Project)
91' KZ1000-P (P = parts)

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