TOPIC:

Hi - New guy here and recent KZ200 owner.

I'm currently working on a 1978 KZ200 and have swapped out the original headlight bucket with a modern one that takes halogen bulbs.

The old bucket had two ground wires connected to the turn signal brackets. They connected to a pair of ground wires in the harness (I assume they go back to the frame or the battery ground). The new bucket doesn't have ground wires from the brackets.


Any suggestions on what I should do to ground the signals? There's only a positive wire coming out of them, so if I need to wire a ground to them where should the connection points be?

Thanks.

How do you plan to mount the turn signal with the new bucket? Those wires are not part of the old bucket. They attached to a collar that goes over the turn signal stem shaft.

You're right - the ground cables don't connect to the bucket but to the collars around the turn signal stems. Thanks for clarifying.

Problem is my new bucket doesn't have those collars.

I put the new bucket in and here's how it is going to hang together. Any suggestions where I need to run a ground wire? Keep in mind, the new bucket is plastic in case that makes a difference.

Stockton350 wrote: You're right - the ground cables don't connect to the bucket but to the collars around the turn signal stems. Thanks for clarifying.

Problem is my new bucket doesn't have those collars.

I put the new bucket in and here's how it is going to hang together. Any suggestions where I need to run a ground wire? Keep in mind, the new bucket is plastic in case that makes a difference.

Get a roll of 18ga wire and some connectors/terminals that look like this:

Ensure the hole in the connector is large enough to fit over the threaded portion of the turn signal stalk.

Attach a piece of the 18ga to the connector. Solder would be best but a crimp should work too.

Remove the nut from the turn signal, place the connector over the threaded part, and reinstall the nut (and washer, presumably).

Do this for both sides. When the turn signals are in place, attach OEM-style bullet connectors (available at Home Depot or wherever) to the new turn signal ground wires and use the existing ground connections. You should have two that are unoccupied since you removed the stock signals.

Hey presto, you're grounded!

Thanks, Nerdy! Looks like I've got a trip to Radio Shack in my future. [cringe]

I'm thinking it should be okay to reuse the original ground wires that came out of the collars. I would just strip the ends and put the O connectors on that you suggested. Does that sound doable?

The collar is also part of the rubber mounts used to isolate the headlight from vibrations. Those ribs on your new bucket look like they would interfere with using the rubber mounts. You may want to consider grinding down the ribs and enlarging the hole to use the rubber mounts. Kawasaki had problems with headlight filaments breaking prematurely on the early Z1's with a solid bracket mount to the headlight bucket. They discontinued the bracket in 74 and released a service bulletin for dealers to remove them from 73's.

Stockton350 wrote: Thanks, Nerdy! Looks like I've got a trip to Radio Shack in my future. [cringe]

I'm thinking it should be okay to reuse the original ground wires that came out of the collars. I would just strip the ends and put the O connectors on that you suggested. Does that sound doable?

You can certainly do that. I like to use new wire and components where possible: they don't cost much and may help to avoid problems down the road.

And you can go to HD or Lowe's if Rat Shack makes you cringe.

Stockton350 wrote: Thanks, Nerdy! Looks like I've got a trip to Radio Shack in my future. [cringe]

I'm thinking it should be okay to reuse the original ground wires that came out of the collars. I would just strip the ends and put the O connectors on that you suggested. Does that sound doable?

I agree with Nerdy's recommendation and also wouldn't cut the original wires. Where the ground wires plug into the original harness should be a coupla bullet connectors. So just unplug them and make a new ground wire with the eyelet on one end and a new male bullet connector on the other.

Thanks to everyone for the suggestions. Here are some pics of what I did. Not perfect, but at least I've got a headlight now.

The new bulb assembly vs the old one:



Ring terminals, rubber rings to hopefully reduce vibration, and a wiring harness for an H4 headlight bulb:



All the stuff I put together before installation:



Signals installed with ground wires on the bolts:



Testing the new lights

Stockton350 wrote: Thanks to everyone for the suggestions. Here are some pics of what I did. Not perfect, but at least I've got a headlight now.

The new bulb assembly vs the old one:

Ring terminals, rubber rings to hopefully reduce vibration, and a wiring harness for an H4 headlight bulb:

All the stuff I put together before installation:

Signals installed with ground wires on the bolts:

Testing the new lights

Outstanding! Looks like you did a fine job. I'm glad it went well. Those rubber grommets on your turn signals fit nicely between the strengthening ribs (?) on the headlight shell.

i also replaced the sealed beam with an H4 headlight - makes quite a difference. My replacement headlight was about 1" narrower than the OEM, so I alternated flat washers and neoprene washers to make a .5" stack for each side. I don't know how much it will do for vibration but it will work until I can replace the ears this winter.

Thank you! Happy with the conversion so far.

I'm hoping to swap the turn signal bulbs out for LEDs so I'm hoping vibration won't be an issue.

Stockton350 wrote: Thank you! Happy with the conversion so far.

I'm hoping to swap the turn signal bulbs out for LEDs so I'm hoping vibration won't be an issue.

You're probably aware of this already but you'll need to swap the flasher unit as well. The LEDs put a lot less load on the circuit and they'll basically flash like strobe lights.

I went with halogen replacement signals from K&S - found them on Amazon. They're very bright and look good (and didn't require a new flasher).