handlebar switch gear - 1981 KZ650

So, I've got this project bike for free. The switchgear, both left and right hand, are in bad shape. I've been working on the RH one and the switches don't appear to be working since resistance remains infinite regardless of position. But, I'm having difficulty finding any used ones that work. Are there aftermarket ones available? I cannot find any on eBay. I did find aftermarket ones for an earlier KZ900, but the connectors are different, and I don't know what else would be different with them since there's an extra switch on the RH control. Has anyone had success taking these apart and refurbishing them? Are there other KZ models out there that fit this bike? Any help is appreciated. 

I've added a photo of what I'm dealing with. I'm really worried about those screws snapping off if I try to get them out. The other half of the switch assembly is just as bad. Rust everywhere. I'm wondering if I should just buy a used one that isn't rusty. 

You might want to open them up and try to figure out what's wrong.  Most hand controls are quite simple inside.  Maybe a good clean out and lube with dielectric grease will solve the problem?

At one time it was common to see China re-pops on eBay but I have not looked in years.

Hi, the z1/kz aftermarket will work just pop the pins out and swap the connector, 650 has 6 pin, z1 has 4 pin, and if you research it a bit you’ll have switched lighting, the switches are the same, they just  removed the lighting switch from the shell, for always on lights, those connectors and brass pins are available from vintage connections, also amazon has complete kits and the crimp tool, not hard to do good luck

As mentioned, KZ900/Z1 aftermarket switches will work but you'll lose your HAZARD feature available on your LH handlebar switch. As Nessism mentioned, just clean-up what you have. Things that commonly go wrong are the RH switch ON/OFF/ON selector knob freezing-up. Don't force it!! It's a rusty singular detent ball bearing. Often happens on these, just replace. Readily available at the hardware store for 15cents. Check the "lighting", if you have it, breadboard for loose soldering on breadboard and board warping. LH I've often found the "factory" soldering on the Hazard breadboard is iffy and they just fall off. Also LH HI/LO headlight switch plastic is brittle right off the dealership shelf and they often snap off right at upper switch half. Could need more, can't see what you're seeing?? I have Tupperware containers of this type stuff though.

asphalt900 wrote:

As mentioned, KZ900/Z1 aftermarket switches will work but you'll lose your HAZARD feature available on your LH handlebar switch. As Nessism mentioned, just clean-up what you have. Things that commonly go wrong are the RH switch ON/OFF/ON selector knob freezing-up. Don't force it!! It's a rusty singular detent ball bearing. Often happens on these, just replace. Readily available at the hardware store for 15cents. Check the "lighting", if you have it, breadboard for loose soldering on breadboard and board warping. LH I've often found the "factory" soldering on the Hazard breadboard is iffy and they just fall off. Also LH HI/LO headlight switch plastic is brittle right off the dealership shelf and they often snap off right at upper switch half. Could need more, can't see what you're seeing?? I have Tupperware containers of this type stuff though.

Hi Clay I have just sent you a PM on a different subject, your experience would be appreciated 

asphalt900 wrote:

As mentioned, KZ900/Z1 aftermarket switches will work but you'll lose your HAZARD feature available on your LH handlebar switch. As Nessism mentioned, just clean-up what you have. Things that commonly go wrong are the RH switch ON/OFF/ON selector knob freezing-up. Don't force it!! It's a rusty singular detent ball bearing. Often happens on these, just replace. Readily available at the hardware store for 15cents. Check the "lighting", if you have it, breadboard for loose soldering on breadboard and board warping. LH I've often found the "factory" soldering on the Hazard breadboard is iffy and they just fall off. Also LH HI/LO headlight switch plastic is brittle right off the dealership shelf and they often snap off right at upper switch half. Could need more, can't see what you're seeing?? I have Tupperware containers of this type stuff though.
 

Thanks. The rotary switch on the RH control does turn, but the ohm meter says nothing changes. The screws, etc. are rusty. I'll make an effort to take it apart or something. I'm concerned that the screws are frozen in there but I guess that's par for the course on this project. I was looking for an easy solution but it looks like there isn't one. 

Three little 3mm screws and the RH upper switch comes off as assembly. Pop off the E-Clip and you'll find 3 springs/halfmoon brass plate and that ball bearing. Here's photo of what they look like. Ya got it for the best price, put some elbow equity in it. No Totally Free Lunches, ha. Let me know what You need, have parts ya can't find out of any Kawasaki Catalog! 

1981 KZ650-H1 wiring diagram >> diagrams.kz650.info/wiring/images/KZ650-H1.jpg
from the kz650.info site. the forums are gone .
RH control from Z1Ent wired to a csr >> kzrider.com/forum/4-electrical/614218-us...enterprises?start=12
kzr topic w a couple of pics .
RH KZ900 on ebbaayy w ON-PO-OFF  >> httpX://www.ebay.com/itm/193088556563 ... link disabled >> change the X to s .
the kill switch & starter button wiring is probably straight forward. not sure about the lighting. but as indicated by jwfels it should be simple as well. the csr has 3 wires connected >> csr brown is a power wire from the igntion switch, so it provides power to the other two wires (blue/white & brown/white). if doable, I would consider removing the toggle and jumpering the connections and filling the slotted orifice w rtv or permatex liquid metal. and black out the on-po-off lettering.

Persons are pushing you to the darkside, ha. I hate the darkside, aka, repop aftermarket, heh. Show a picture of controls and connectors when you get a chance, I've containers of them plus replacement bits if not adequate.   

I've attached a photo of the switch to my original post. It's really rusty. 

asphalt900 wrote:

Persons are pushing you to the darkside, ha. I hate the darkside, aka, repop aftermarket, heh. Show a picture of controls and connectors when you get a chance, I've containers of them plus replacement bits if not adequate.   
 

I've put up a photo of the switch. Rust everywhere.