Gen 1: 2004-2005 Wiring problems, need help!!! - Kawasaki ZX-10R.net
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post #1 of 13 Old 06-13-2019, 09:30 AM Thread Starter
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Wiring problems, need help!!!

Does anyone know where this black with orange dot goes on the 04 zx10r. I can’t find it in my service manual at all. Please help!!!
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post #2 of 13 Old 06-13-2019, 10:10 AM
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Is that a US harness or one from another country?

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post #3 of 13 Old 06-13-2019, 10:34 AM
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Regardless which region it may be, there are very few single wire connections in that harness. I don't recall if the "Euro" stuff had a narrowband O2 sensor, but that would be one. The oil pressure sensor is another (not it in this case, though). Aside from that you typically only have single wire connections to ground, as all the other sensors are 2 or 3 wire. It could be a pass-though for power for another harness, but I'm not an expert on the first gen harnesses.

If you have the harness in hand you can either trace it back to the ECU plug and see what pin it is on (or what other wires it may T in to). You could also use a ohm meter/volt meter to do the same. Once you know the ECU (or relay box) pin location it will be a drop in the bucket to figure it out from there.

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post #4 of 13 Old 06-13-2019, 10:38 AM Thread Starter
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To be honest I’m really not sure, I replaced the harness a few years back and had a shop put it in. When they installed they tapped that black orange wire direct into the stator. I just had a valve job done on the bike by an authorized Kawasaki service center and they pointed it out to me and said it doesn’t belong there. I started researching and couldn’t even find the wire on the wiring diagram for us or international harness. I’m completely lost!
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post #5 of 13 Old 06-13-2019, 10:52 AM
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In the parts fiche: the generator has a sub-harness with 5 plugs on it... one of those is a break out with a single wire/plug. If it's in that region I would look at that generator sub harness and see if it's still there. Being that it's a sub harness it may be a little difficult to find or read that in the service manual.... If I can find a copy of said service manual I'll look it up.

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post #6 of 13 Old 06-13-2019, 11:13 AM
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So, I think I found it. The generator has a sub harness as mentioned before, and there is a single wire breakout on it. If you look at the wiring diagram it is a little confusing as they show the connector in a strange way. Attached are 2 snips that show how the diagram shows it. Blue circles are the main generator charging wires, red is the one wire breakout. The diagram is not to scale, so the fact that they dont show the breakout near the actual generator is a little misleading.

That wire is off of the generator to the relay box; it's what causes your headlight to turn on once the bike starts running. :) Once it is on it stays latched through relay box trickery. :)
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post #7 of 13 Old 06-13-2019, 11:48 AM Thread Starter
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After chasing this wire indicated back on the diagram it shows that it is a black wire rather than a bk/o wire
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post #8 of 13 Old 06-13-2019, 12:36 PM Thread Starter
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below is a picture of the wire from the service manual
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post #9 of 13 Old 06-13-2019, 02:57 PM
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Those orange dots are not orange on the diagram designation..... BK/O would be a continuous orange stripe that runs down the length of the entire length of a black wire.

Also; you could do a voltage check on either side of the wire when the bike is running.... that would tell the tale. :)

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post #10 of 13 Old 06-13-2019, 02:59 PM
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here is an ebay link to someone selling the sub harness.... notice the male, single wire white plug in the photos....

https://www.ebay.ie/itm/2004-2005-KA...item1cc6cb778c

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