Some Hard-to-Find Kenwood Parts

 

I was shocked to see so many parts needed for successful restoration of these wonderful rigs going away.  I guess in this day of surface-mount digital equipment, there is just not enough demand to keep manufacturer's production lines going.  Since I repair and restore these Kenwood classics, I have to find or make what's needed to keep these rigs up and running.

Here's some parts that I have available for your restoration efforts, I will try to continually add to this list.  I have accumulated several donor rigs, so I have Kenwood coils, caps, meters, power transformers, etc. on a limited basis.  Please feel free to contact me with your needs for specific items.

 

SHAFT COUPLER
TS-520, TS-530, TS-820, TS-830

These are getting hard to find, and very expensive for the 4-setscrew units.  I have tooled up, and make exactly what we need for the Kenwood bandswitch and other shaft repairs. 

Solid brass, with four 3mm x 0.5 x 3mm setscrews.  The outer diameter is only 0.375", so you can install it without taking the radio apart!  See INSTRUCTIONS.

The SC-M2 is the 1st major revision to my original shaft coupler in over 4 years! The new shorter length replaces the Kenwood nylon couplers perfectly, even fitting the close-quartered TS-820 bandswitch coupler space. 

These are made for metric use, for Kenwood, Yaesu, and other Japanese brands, with 0.236" shafts.  The nominal 0.238" I.D. is a nice slide fit with the metric shafts, but will not fit 1/4" U.S. shafts. 

SC-M2    8.95 Each

SC-M2-3        (3-pack)  24.95

SC-M2-10    (10-pack)  74.95

Click here for a movie showing them being made!


4-PK KENWOOD PANEL LAMPS

The right shape, size and wattage for replacement of all Kenwood Panel Lamps including TS-520, TS-530, TS-820, and TS-830 models.

Rated 12V, 50 ma, 4mm dia., 6" wire leads.  Long life, and brightness & color matches originals perfectly.

PL-4   5.00 per 4 PK

PL-20 19.95 per 20 PK

 

RL-1 REPLACEMENT RELAY
TS-530S  TS-830S

A problem with this relay can cause both receive and transmit problems of an intermittent nature.  Kenwood Part# S51-4401-05 is actually an Omron relay, model LZN4,  which was discontinued many years ago.

Here is a pin-for-pin drop-in replacement that will cure that intermittent ALC and slow comeback receive you may start to experience.

See how to locate, diagnose, and test your relay, here on the RL-1 Page.

Kenwood Parts has replacements for $38.21 + S&H -  I was very happy to find this unit instead!

On the left is the Omron part, and the new replacement on the right.

RL-1    19.95 Each

Click HERE for more information.



 

REMOTE VFO CABLE KIT
TS-520, TS-820, TS-520S and TS-820S

NEW!

All the parts necessary to build the hard-to-find VFO cable for the 520/820 series of hybrids used in conjunction with a VFO-520 or VFO-820.

This kit contains two 9-pin miniature socket extenders that I have modified for use as VFO plugs, together with 25" of 9-conductor shielded cable.

You do the assembly, and provide the solder and about an hour of your time.

The top picture shows the parts provided, and the bottom picture shows a completed cable assembly.

Assembly Instructions are available here.

CA-9      12.50

Please Note:  This is a Kit and must be assembled by you!

 

 

VFO PLUG for 520/820

Enables the internal VFO in a TS-520, TS-820, TS-520S or TS-820S when a Remote VFO is not present.

I fashion these from 9-pin miniature tube socket extenders, and they are prewired and ready to plug in and use.

Not for cable use, use the CA-9 (above) if you need to make a Remote  VFO cable.

PL-9            5.95

 



REMOTE VFO CABLE KIT
for TS-530S and TS-830S

I was going to offer completed cable assemblies, until I realized that it took me an hour to assemble one! 

These kits contain the two hard-to-find Kenwood-style 8-pin DIN plugs (The ones with the strange spacing) and a 25" length of nice multiconductor shielded cable.  The cable is round, very pliable, and works perfectly.

The top picture is the kit components, and the bottom picture shows a completed assembly.  All you add is solder and an hour of your time.

Assembly instructions are available here.

CA-24    12.50

Please Note:  This is a Kit and must be assembled by you!




KENWOOD 520/820 POWER CORD


Replacement Power Cord for Kenwood TS-520, TS-520S, TS-820, and TS-820S.  Proper 2-wire construction (see FAQ), with polarized plug.  .

PC-2    24.95 Each.


REPLACEMENT HANDLES
for TS-520S, 820S, 530S, 830S

Two sizes and configurations of handles to replace the broken or missing handles on your rigs.  These are attractive vinyl handles with unbreakable spring steel inserts to easily lift your 40lb. treasure!  The covers are chrome plated for lasting looks.  Stainless steel oval-head mounting hardware is included.


HDL-52 fits 520/820       9.95

HDL-53 fits 530/830       9.95
 

KENWOOD DG-5 CABLE SET

Complete set of cables as needed to connect a DG-5 digital display unit to a TS-520S or TS-520 with a DK-5 Adapter.

This set includes a 12V power cable with keyed connectors and inline fuse, and a molded 3-cable assembly that can handle the 35 MHz HET signal needed for proper operation. 

Gold plated contacts, 18"+ length matches originals and works perfectly.

CA-5     24.95/Set

 

RESISTOR KITS FOR FINAL REPAIR

Resistors are not hard to find, but it's often a pain to find exactly what you need in small quantities, and shipping and handling fees may get excessive.

I have 2 Kits, one for the 520/820 series, and the other for the 530/830 series.  Included are the cathode resistors and a set of 3 screen resistors. These will replace the resistors that are usually damaged or destroyed in rigs that have been overdriven. All resistors are non-inductive metal film or metal oxide, flameproof construction, the good stuff.

RK-52 for 520/820  1.99 Each
Consists of (2) 10 Ohm 1W 5%, (2) 100 Ohm 1/2W 1%, (1) 470 Ohm 1W 5% 

RK-53 for 530/830  1.99 Each
Consists of (4) 20 Ohm 1/2W 5%, (2) 100 Ohm 1/2W 5%, (1) 470 Ohm 1W 5%

Click here for "Why not Supersize?"

 

KENWOOD HIGH-VOLTAGE REPAIR KIT

If your HV seems to sag a bit under key-down, odds are that your 25+ year old HV electrolytics have decreased in capacitance, or increased in ESR.  Either way, it's time for replacement.  This kit provides 2 modern high quality 120uf 500WVDC electrolytics, two 0.01mfd 1KV bypasses, and two 470K 1W 500WVDC resistors to restore the entire HV filter section.

The new electrolytics fit the existing mounting hardware perfectly, and the 20% increase in capacitance will provide higher power output.

HV-150B  Kit   24.95

Yes, I have plenty of stock on these hard to find caps . . .

 
 

KENWOOD FINAL CAGE PARTIAL REPAIR KIT

Kit consists of the 3 most commonly damaged, hard to find parts when the final section has been overdriven.  Includes:

  • Class1 0.001 mfd 3 KV Low DF Disk Ceramic kit
  • 0.01 mfd 2 KV Disk Ceramic
  • 6.8 uh 500ma RF Choke

These are top-quality parts selected for their stringent requirements!

Click HERE to see details of what they replace

FR-100 Kit    5.99

Repairman's 5-pack  24.95


KENWOOD MIC CONNECTOR

4-Pin Mic Connector for all the Kenwood hybrid models. 

MC-4         3.99 ea


PANEL FASTENERS  

Snap in Plunger and Grommet sets fit the original mounting holes perfectly!  Used on the TS-520 and TS-520S, these fasteners attach the side cover plate that conceals the VOX and bias adjustment pots.

Plunger heads are 0.1" taller and shaped to allow for easier removal - No prying tool needed.  Bottom photo shows the original (back) and the new (front) fasteners installed.

PG-200 includes 2 complete assemblies (two plungers, two grommets), all that's needed to properly attach the side door.

PG-200 Kit  (2 pairs)    3.00
Enough to attach 1 door

Repairman's 5-pack (10 pairs) 13.50
Enough to attach 5 doors   


CHASSIS HARDWARE KIT  

Replace those missing or corroded screws in your hybrid!  These screws are used throughout the hybrid chassis for attaching the final cover, fan housing, and just about everything else! Very hard to find, with the trucated point and 1mm thread pitch.

Heavy zinc plating on steel, a snug fit in the original threads, will even repair some holes stripped or crossthreaded by improper hardware.

HW-50  Pkg/25 screws   2.50

HW-100  Repaiman's Pkg/100   9.00





KENWOOD CASE HARDWARE KIT

Beautiful 18-8 Stainless hardware matches the patina and sheen of the original hardware, but this time, no more rust!.  This Kit consists of twenty M4 x 8mm Phillips Pan Head case screws, enough for any 520, 820, 530, or 830.   It also includes four M3 Phillips Oval Head speaker screws also in 18-8 SS.

Great for sprucing up your rig, essential for a restoration.

HW-10  Pkg 24 Screws    3.99


CABINET FEET - SET OF 4
With Hardware

Natural rubber feet with molded-in reinforcing washers for long life.  28mm diameter by 16mm tall, tapered as shown.  Fits all TS-520, 820, 530, 830.  Includes M4 x 0.7 x 10mm pan head Phillips screws for attaching to Kenwood chassis.

These feet will resist the cracking commonly found in the originals.

FB-40 Set of 4 Feet    4.00

FB-45 Repairman's 20 Pack  16.00

Includes mounting hardware

 

CASE HOLE PLUGS

These Nylon plugs fit the TS-820's, SM-220's, and R-820's nicely.  You can replace those crumbling rubber plugs and restore the finished appearance to your rig.

This is what I've been using for restorations, now you can freshen your rig's appearance on the cheap!

HW-25   Pkg/3    1.50

 

6A 250VAC FUSE

I get so many rigs in with 32V automotive fuses that I suspect the proper fuses are less common on your grocer's shelves! 

The 32V fuses may not open (fuse) properly, you really should use the right part.  3AG fuses rated 6 Amps, 250VAC fast blow.

FS-106   Each   0.65

FS-106-10 Repairman's 10-Pack 5.50

 

12BY7A DRIVER TUBES

I have a limited supply of NOS 12BY7A driver tubes, from several manufacturers.  I test them all, they must test new or I will not sell them.  While my supply lasts, you can get them at a very reasonable price.  Provided in the original manufacturer's packaging.

12BY7A NOS    11.95 


KENWOOD ALIGNMENT TOOLS


It is far better for your rig if you can keep metallic tools as far from the alignment adjustments as possible!   Please, don't ever use allen wrenches to try to adjust your 520 & 520S coils - The core will simply break and become immovable.  Also, never, ever use a metallic adjustment tool for neutralization!  You will make big sparks, and you could become an SK!

AL-1 is a double-ended nylon hex alignment tool that fits the coils in the 520 and 520S perfectly.  Two ends, twice the life.  5.5"L

AL-1    2.75

AL-2 is a double ended 1/4" hard plastic screwdriver with thin blades that will fit the neutralization cap on the 520, 820, 530, and 830 series.  It is tough enough to take the torque in that thin slot - Mine is 2 years old, tested on over 200 rigs.  6.75"L.  It also slides under the Kenwood knobs and pops them free without marring the panel.

AL-2    2.75

AL-3 is superb for adjusting the Kenwood relay contacts!  It has a bifurcated (split) point that allows you to bend the flat contacts anywhere you desire - Very hard to do with any other tool.  I've been using one for 40 years and never realized these are now sold  as "soldering aids!"   Made from tool steel with a black oxide finish for long life.

AL-3   3.50


 

DUMMY LOAD RESISTOR KIT

Kit of twenty (20) 1K 3W 5% Metal Film resistors to build a dummy load as shown on my web page here:

http://k4eaa.com/dummy.html

Selected especially for their accurate impedance at 1K resistance out to over 200 MHz.  Good power handling, could be used air-cooled for short durations, such as 100W for 10 seconds key down, or several minutes in a mineral oil filled quart can as shown at the above link.

NEW!  Now the kit also includes a BAV21 diode!

LK-R1    12.50 

 

See my FAQ for information about new shrinking part sizes and RoHs here:

http://www.k4eaa.com/faq.htm


EXTRA LARGE
SCHEMATIC LASER PRINTS 

High quality schematics printed on large format 24" x 36" sheets.  These can actually be easily read by most of us!

These are black and white prints made on a very large laser printer and are extremely crisp and legible.   I have these PDFs available for free download here:

http://www.k4eaa.com/schematics.htm

The problem is getting them printed in a large size at a reasonable cost.  These are printed from the original HUGE files from my scanner, before compressing for download.

The price includes USPS shipping, and a storage/mailer tube with plastic end caps for safe storage between uses.  Prints are rolled, not folded, into 24" x 2" sturdy cardboard tubes.

If you're like me, you might even consider framing one for your shack!  I will be adding more schematics as time and finances permit, right now the TS-830S main schematic is available.  See the PDF link, above, for content.

SM-830S  12.99
TS-830S Main Schematic

Includes shipping within the U.S. and a reusable storage tube.

Save!  Up to five prints will ship in the same tube for 7.50 each additional print.  Great for clubs, groups, and friends.

 

 

SHIPPING AND ORDERING INFORMATION

Most small items, or combinations of small items will ship in a padded mailer or small box via USPS 1st Class Mail for 2.99 or 3.99 depending on size.  If you prefer Priority Mail, up to one pound ships for 5.99.  I also ship to Europe, Australia and Canada.

Please drop me an email for full contact info and payment details.  I will send you an invoice you can then either print and mail with a check, or copy and paste into your PayPal payment.

When you mail or email your order to me, please include (1) your order, (2) your shipping address, and (3) your email address.   Please don't make me search through thousands of emails trying to guess if either "Joe" or "Joe Snuffy" is really jrs102@bilge.net . . .  8^)

Thanks, and Best 73's, Ken K4EAA

 
 
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All Photos and content copyright 2005 - 2009 K4EAA, Ken Kemski.

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