With the possible exception of racing mechanics that spend every waking hour building motorcycles, wiring a motorcycle requires the aid of a service manual. Your Kawasaki ZZR600 has a wiring harness that consists of numerous measured branches for a specific layout. Once the harness is installed, you reassemble the motorcycle and connect the components and accessories to the wiring. The basic circuits are divided into two parts: the engine's electrical systems and the bike's accessories. You wire a Kawasaki ZZR600 with the engine installed and the fairings, gas tank, seat, instrument cluster and lights removed.
Stabilise the motorcycle on a repair stand or on wood blocks. Lay the wire harness alongside the motorcycle and turn to the electrical system section in your service manual.
Look at the table of contents at the beginning of the electrical system section in your service manual. Turn to the pages listed to identify the front, middle and rear of the harness by comparing the connectors and wire colours to the diagrams and descriptions in the manual. Identify the battery leads.
Position the centre portion of the harness atop the engine at the area of the rider's seat. Identify the wires and connectors for the ignition coil, CDI box, ignition timing and the fuel pump. Route the connectors to each of the particular components.
Identify the remaining branch wires and connectors for the electric starter, radiator fan and the temperature sensor. Route these wires and connectors to the appropriate locations.
Fasten the middle section of the harness to the upper frame tubes using nylon ties. Establish which component wires can be fastened to the motorcycle frame and fasten these with nylon ties. Position the battery wires and connectors at the area of the battery and fasten the wires to the motorcycle frame. Do not connect the battery leads to the battery at this point.
Look at the table of contents at the beginning of the electrical system section in your service manual. Note the pages for the lights and accessory wiring.
Identify the branch wire and connectors for the tail light and the rear turn signal lights. Route the branch wire along the upper frame tube and position the connectors. Fasten the branch wire to the frame tube.
Route the branch wire for the instrument cluster and the ignition switch along the upper frame tube. Position the connectors and fasten the branch wire using nylon ties. Route the branch wire and connectors for the headlight and the front indicators to the front of the motorcycle. Fasten this branch to the frame behind the steering headset.
Identify and route the wires and connectors to the starter switch and the turn signal switch at the handlebars. Locate the headlight relay, turn signal relay and the brake-light switch. Identify and route the wires and connectors for each.
Install the motorcycle fairings, gas tank and the seat. Follow the procedures in your service manual and install the electrical accessories and lights. Connect the accessory wiring circuits to the accessories, switches and lights.
Take your time and make the wiring as neat and tidy as possible. Keep wires away from the engine and the steering stops on the headset.
Do not pull or stretch wires to make a connection. Back up and re-evaluate the wiring routes.