Yeah, radiator placement and selection for me turned out to be laziness really. I had the ninja rad and didn't feel like trying to figure something else out... and I wanted fans - I live in the desert now so heat is an issue.
as far as the wiring harness i would really like to know what all you did to yours cuz i need help elimiating un needed stuff on mine. any help would be greatly appericated!!
Well for electrical, I had to rebuild the ENTIRE harness from scratch. Its actually not all that bad and mine is a bit complex due to the all the extra wiring I did for the fans, HID headlights, LED tail lights. I basically got all of the components that were going on the bike (CDI, Switches, keyed ignition, coils, ect) and sat down with a wiring diagram so I knew what wires on the components were what, and just went to town.
Also, on mine, i designed the electrical system so that the charging circuit would be completely isolated and non-dependent on the main system. This one done for the fact that I tend to venture into a lot of really remote area and if the charging system failed on me, I would still be able to run off battery power for a while to get back. I have a little LED volt meter that shows me the condition of the charging circuit so i can clearly see if it fails. I think it was a walmart "on clearance" thing with 3 LEDs. When running, all 3 lights light up. If i disconnect the charge circuit, it drops to 2 or 1 light so its obvious.
12v feeds from the battery to the ignition, ignition to solenoid, solenoid to starter and cdi/coils, and lets not forget the solenoid to starter button and back, and also out of the keyed ignition to the lights and fan, and depending on if you want the fan to stay running if you hit the kill switch or now is another story.
Its certainly not for the faint of heart. I just centralized my wire bundle and left all my separate leads long so when I fit it to the bike, I trimmed all the wiring to fit. I also used much of the stock Kawasaki harness to cut plugs off and re-purpose them for use on this harness to I could strip it apart, or you could go to radio shack and buy plastic plugs in all kinds of configs but use lot of dielectric grease on them because they are not intended for outdoor use and thus not water tight. I don think I saved my new wiring diagram because im sure it changed when it came down to actually trying everything, but I will look for sure.
If you have a basic understanding of electrical circuits, you will be able to frustratingly work through it. If not, I suggest retaining ALL original wiring and don't muck with it.
Good luck on the project. Your gonna need it. I sure did. I fought that damn thing for 3 weeks until i found out about the stupid resister they hide in the OEM key switch for the Kawi.
- Justin
