TOPIC:

My nut has always been on the right side, too. Where did you find the exhaust? It looks pristine. The build looks terrific!

Got the exhaust from a guy that deals with KZ's here in Germany. Every now and then someone comes in and swaps one out for a 4-1. It's not perfect but it's pretty good - the right hand side is really nice except for a couple of spots on downpipe #4. The left side is pretty good, I'd like to get it re-chromed but the local guy will only do mufflers with the baffles removed (not an option on the KZ1000 4-2 exhaust). It's good enough though, so I should probably just leave well enough alone...

I took all of the wiring off the shelf today. Looks like it should be OK to reuse - I'll check everything when I re-wrap the main loom. After sorting though everything I have a few questions for you guys:

• I can't find this part - what is it and do I need it? www.cmsnl.com/kawasaki-kz1000a1-1977-can...or-voltage_21066026/

 

• There is a long black wire coming off the rectifier. I know this goes to ground, but where does it usually get screwed on? Directly to battery negative?

       

• The brake light failure indicator seems to be connected to the main harness somewhere under the tank. Does anybody know where the mounting plate for this goes?

       

• The flasher relay has three pins. I am assuming this is a combination hazard/indicator relay with a shared positive. The problem is that there are four connectors coming off the harness (as expected with two seperate relays). The hazard relay wires are in the branch for the rear brake light switch and engine ground, the flasher relay wires come off the back section of the harness (near the connector for the tail section). I'm thinking I'll just get two standard relays as I'm pretty sure that was stock. I know that one mounts next to the fuse box, does anyone know where the second one goes?

       

       
       
       

       

wrote:

My nut has always been on the right side, too. Where did you find the exhaust? It looks pristine. The build looks terrific!

I was wondering the same. To me that is the sexiest OEM exhaust KHI built. I’d love to find one in that nice of shape. 

The location of the break light failure switch.

 

The long black ground off the rectifier grounds to the seat lock bolt. Hope these photos help. 

 

The shorter brown and blue go to the rear brake light switch.

Thanks guys, I had a look in the book yesterday after scirocco's post and saw the flasher relay location. Thanks for the info on the rectifier - will see how that lines up tomorrow. Was all good on the rest, except for that wierd voltage regulator and the location of the green resistor for the headlight circuit (although I'm pretty sure it gets bolted to the left hand coil bracket).

Got some new cam bearings and was going to put them in. They were supposed to be original Kawasaki parts but don't look the part. There a 16 shrink-wrapped together. They have STD stamped on one side and 18A on the other - AFAIK the stack bearing shells aren't stamped...

I cleaned up and wrapped the main harness today and managed to get most of the electrics in. Need some flasher relays and a few bits of hardware to get it finished up, will also replace the ground and starter cables. 

 

 

 

 

Does anyone know how the main harness is usually routed under the tank? What goes through the hole in the bracing?

 

Nice tape work on the looms, is that "fabric" tape ? 

Yeah, it's PET fleece stuff from Tesa. Holds up pretty well - has been under the hood of the mini for a few years and looks as good as new. 

The harness goes under the brace where the tank elastic goes. Then wraps around the frame to the outside to get to the relay plate. The oval hole in the center brace is for the carb vent tubes 

stock photo pulled from the internet