Wire gauges, connectors, etc - kz650

Hello All!

In preparation for full resto of my kz I am researching what will be needed. Looks like there is many "bullet" connectors around a bike. Is it good idea to keep same style ? If so, where do I get good quality ones?

Another question is wire gauge. What gauge used through the bike? I have large supply of nice 18Ga wire and wonder if this will do.

What about modular connectors? Is factory style available and where I can get those?

CycleTerminal.com has stock-type connectors & terminal pins and they have a 10-pack of waterproof bullet connector sets. plus other stuff. I got most of my electrical supplies there plus a terminal pin extractor tool set >> white handles. I already had a ratcheting crimper from HF, but the dies were wrong, so I got an open barrel die set from Aircraft Tools on amazon.

Z1Enterprises.com also has connectors & terminal pins plus color wire. Both places have good ratcheting open barrel crimpers >> the crimps are very strong.

I have had good luck with vintage connections

martin_csr wrote: Both places have good ratcheting open barrel crimpers >> the crimps are very strong.

I have greenlee pa8024 crimper, I think that should do.

Thank you for store pointers!

You'll have to figure out how much current each wire will see then account for a little more.
The fuses are meant to protect the wire not the load so choose your fuses based on current capacity of the wire.

Wire calculator
www.wirebarn.com/Wire-Calculator-_ep_41.html

I source my wire from prowire
prowireusa.com

I use Deutsch connectors but that may not look right with your restoration and may be overkill.

F64 wrote: I use Deutsch connectors but that may not look right with your restoration and may be overkill.

I was curious about "general use" wire gauge. Seems like 18Ga is what Z1 sells, it can handle little over 5A current so should be good for most systems in a bike.

Connectors is a dilemma for me. I feel like I need to preserve all "ends" like stock to make any parts replacements plug-n-play. So, those bullet connectors might have to stay (even though I don't like them). It also makes sense because it's much easier to fish those bullets through tight spaces vs bulky plugs.

By katit: I have greenlee pa8024 crimper, I think that should do. ...

Okay. I couldn't find a good pic of the PA8024 to see what type of dies it has.
I forgot to mention that the tool I use does stock-type crimps.

I think this is the place Mikaw mentioned. I use them all the time. They have connecters, wire, sleeves and even a very good crimper tool.

www.vintageconnections.com/

I wouldn't sign off on 18 awg only. At least, I would measure the wire you have on the bike currently . You have to measure the conductor minus the insulation.
Most of the bike could probably be wired with 18 but there are some areas where you may need bigger.
Plus, you should account for any upgrades that you may want to do in the future.

I would stick to the stock bullet connectors.
The Deutsch pins are actually smaller than the bullets and are pretty easy to remove from the connector housing if you have different project in the future.

hardrockminer wrote: I think this is the place Mikaw mentioned. I use them all the time. They have connecters, wire, sleeves and even a very good crimper tool.

www.vintageconnections.com/

Thats the place, thanks for posting the link. I was replying on my lunch and didnt have time to post it.

If you are not worried about making it all original you might consider a Moto Gadget M-Unit.
shop.revivalcycles.com/motogadget-m-unit-blue/
The M-Unit updates many of the electric circuits on your bike.
It is a replacement for your junction box.
I am currently installing one on my 83 GPZ-1100 .

This place has a lot of stuff too.

cycleterminal.com/