1979 KZ650-C3, Handlebar Switch Won't Close!

So...I purchased a '79 KZ650-C3 that had been down, and the handlebars on the right side had bent. I replaced the bars with ones I had from a '78, used the existing on/off switch. But now the switch won't close all the way when I put the screws in, and it's really pissing me off! I'm wondering if maybe the wrong switch is on there; not sure of the bike's history. Picture 1 shows the switch from the top, #2 the misaligned case. Anyone know if this is the correct switch for this bike? Thanks for your help!

Some controls have a peg that have to fit into a hole on the bars. Does yours have this peg? I usually remove the peg on worn out controls (not pristine ones) since most KZ controls are made of metal and can clamp down hard enough to work without the peg.

Not sure on the 650 but I've seen a tit/pin formed into the top switch cover 0n my 1000 that has to engage into a hole in the bar... its there so you don't twist the entire control when grabbing a hand full of throttle

Amazing! Yes, the KZ650 has a little peg that fits into a little hole in the handlebars. It is there to ensure that the control cannot twist out of position. Rather than getting pissed, the original poster should simply take a minute to examine the problem and correct it. Ed

Hi Ed, I don't usually post anything here unless I'm really at my wits end...I didn't see or notice this after about an hour of fooling with it, but I'll check now and appreciate the help!

Assuming the handlebars are stock there should be a hole for the pin to engage. If they are aftermarket and don't have the hole you can drill one. If so, ask first and maybe some one can help identify exactly where the hole should be drilled. Ed

Sans the hole. FWIW. In some old topics some say the hole & peg aren't necessary, so they grind off the peg. It has been surmised that the hole is just a locator to simplify the factory installation. I prefer to have the hole & not alter the housing.

I drill a hole using a titanium-coated drill bit. Before drilling, I make a dimple using a big nail & hammer. not sure if that's necessary, but I didn't want the drill bit to skate around on the new chrome. To protect the bars from scratches I wrap them w masking tape, plus milk jug plastic secured w masking tape near the hole.

Yes the pin and hole others are talking about should be looked at. Would also say take a look at the cable/wires going into the control unit. Stock they were inside the handlebar. Your pic shows that you are not running them through the bar. Make sure there is room, I cut a small hole in the lower control to allow the cable/wires to enter the control.

gd4now wrote: Would also say take a look at the cable/wires going into the control unit. Stock they were inside the handlebar.

I dont think they did on a c3. Thought it was only b's that had wiring inside the bars.

martin_csr wrote: Sans the hole. Before drilling, I make a dimple using a big nail & hammer. not sure if that's necessary, but I didn't want the drill bit to skate around on the new chrome.

You know there's actually a tool for that, right? It's called a center punch.

Warren3200gt wrote:

gd4now wrote: Would also say take a look at the cable/wires going into the control unit. Stock they were inside the handlebar.

I dont think they did on a c3. Thought it was only b's that had wiring inside the bars.

Not just the b's. My 1977 KZ650-C1 came with the wiring inside the bars. I could be wrong, but I believe Kawasaki started putting the wiring outside the KZ650 bars in 1979. Ed

By Nerdy: You know there's actually a tool for that, right? It's called a center punch.

Thanks. I don't have a that tool, but I do have a million nails. Do you know how many times I've needed a center punch?. Twice. maybe thrice. perhaps a few more times if I think hard enough. :laugh: