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 are some parts that I have available for your restoration efforts, I will try to continually add to this list. 

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Includes USPS Price Increases effective Jan 27, 2013     

 
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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.

Will fit all hybrid models, but is especially useful to replace the breakage-prone nylon band switch coupler on the 820, 530 and 830 models.

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            (1-Pack)  8.95
Quan      


SC-M2-3        (3-pack)  24.95
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SC-M2-10    (10-pack)  74.95
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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   (4-pack)  5.00

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PL-20 (20-pack)  19.95

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RL-1 REPLACEMENT RELAY
TS-530  TS-830

Finally!  The long awaited K4EAA relay module that replaces the now obsolete NF4EB-12V and Omron parts.

It is constructed from an FR4 PC module that has the identical size and pin placement of the original relay.   Except that this time, two commonly available (from many mfrs.) DPDT relays are used, and plug into the relay module using two high quality machined pin IC sockets with gold contacts and rated a full 3A!

The top photo shows the complete RL-1 module that you will receive, ready to install on your board.   The bottom photo shows what the module consists of, and how easy it is to replace relays with no unsoldering of the module.

The relays are large,heavy-duty Tyco D2n style, with AgNI gold covered contacts, rated 3A,  250VAC, with excellent low current characteristics.  Thay are rated for 15,000,000 mechanical operations and 2,000,000 electrical operations at 6V 100ma - Close to our use!

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

RL-1    (1-Pack)   24.95

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RL-1 image

Spare Relay Set for RL-1
TS-530   TS-830

Spare set of Tyco/Axicom relays for the RL-1 Relay Module.   Just in case the industry ever abandons this ubiquitous form factor, you'll be prepared!

D2n, 12VDC, non-polarized coil, 3A 250VAC gold contacts, 6ms operate time.  Package of two.

RD-2N  (2-pack)    7.99

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Tyco Relays
 

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 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.

Obsolete 

   *** No longer available ***




 

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

Now shipped with the original Kenwood cupped screw-on plugs! 

(PL-9K Shown Below)

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 Kenwood 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-9K      14.50

SOLD OUT

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, or can be used to build cables.

These are the original, last remaining stock of the Kenwood 9-pin connectors.  The back cover threads onto the pin carrier, which features easy-to-solder solder cups.

For use as a Remote plug, pins 8 and 9 must be jumpered.

PL-9K          6.95 ea

SOLD OUT


 

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    14.50

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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.

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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 designer oval-head mounting hardware including nuts & washers is included.


HDL-52 fits 520/820       11.95
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HDL-53 fits 530/830       11.95
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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

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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

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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

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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?"

Click here for Charles, KC2YWZ page on replacing screen & cathode Rs.

 

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.

INSTALLATION INSTRUCTIONS

HV-150B  Kit   24.95

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


HV CAP MOUNTING CLAMPS

Set of two mounting clamps with all the hardware necessary to mount either the original or the HV-150B replacement kit.

Needed if your radio no longer has the original clamps.  Capacitor not included!

HVC-100 Kit    5.49

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SCREEN & DRIVER CAP KIT


Kit of four (4) 22uF 450V Heavy Duty 105 degree C replacement caps for filtering the screen and driver voltages in all models.

The exact size, shape, and lead spacing as the original 530/830 units, but with improved ripple current and temperature ratings.

These can also replace the dual section units in the 520/820 models by mounting the caps on an 8-lug terminal strip.

HV-22 Kit    9.95
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KENWOOD FINAL CAGE PARTIAL REPAIR KIT

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

  • 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

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Repairman's 5-pack  24.95

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SCHOTTKY DIODE KIT

Package of four (4) 1N6263 Schottky diodes for use as replacement diodes for the Kenwood double balanced diode mixers.  Lower noise figure, better linearity, modern replacement for the 1N60 Germanium diodes used in the originals.

SD-400 Kit   1.99
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KENWOOD MIC CONNECTOR

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

MC-4         3.99 ea
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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)    3.99
Enough to attach 1 door

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PG-200-5  (10 pairs)   16.95
Enough to attach 5 doors   

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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   2.75

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HW-50-4   Pkg/100 Screws  9.95 Quan     





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

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K4EAA K1 Knob
KB-1 Replacement! 

Finally!   The K1 upgrade knob  is now a reality!   A large billet of 6061-T6 aluminum machined into a beautiful knurled knob with a ball-bearing supported spinner!   The ultimate knob for Kenwood radios.

Beautifully machined, ultra low pressure bead-blasted, and professionally anodized to a durable bronze color matching the original Kenwood KB-1 knob!

See the complete story here:

http://k4eaa.com/k1-knob.htm

If you are tired of seeing beat up KB-1's going for $150+ on eBay, look no further.  Smooth, heavy, and beautiful!

K1-B    (Original Bronze)
K1-DB (Dark Polished Bronze)
K1-C    (Clear)


K1 Temporarily Unavailable

Find more info HERE



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    4.99

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FB-45 Repairman's 20 Pack  21.95

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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

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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

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

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12BY7A NOS DRIVER TUBES

I always seem to 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. 

12BY7A NOS    13.95 

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NOT QUITE NOS 12BY7A 

While hunting down and buying niches of NOS 50 year-old vacuum tubes for our rigs, I run across some in a lot that test fine, but have had the lettering wiped from cleaning attempts, water damaged boxes, test results written on them, scruffy cosmetics, etc.

These test very good, most as new, so I save them - I can't throw away a perfectly good tube!   Well, now I have a bunch saved up, and I'm offering them to you cheap.   Guaranteed to test and work fine, or you can return anything you don't like for refund or replacement - Your choice!

C-12BY7A      6.95
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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    2.95

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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    2.95

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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

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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 

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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

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

 



Replacement Sprockets

for Kenwoods

Gregory Graham, NR6C is printing replacement sprockets for the Kenwood Drive control!   You can order them at his website:

http://nr6c.com/sprocket.htm




sprocket

How to Mail in your order if you don't want to use online Payment -  U.S. Orders Only

You must pay via a USPS Postal Money Order.   Send your order with payment to: 

You can use the shopping cart to assemble and price your order.  Just don't check out!  When finished, print your order and mail it to me with your name and address, and M.O. payment enclosed.   Please remember to include 4.99 shipping.

Thanks and Best 73's, Ken K4EAA

 
 
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All Photos and content copyright 2005 - 2014 K4EAA, Ken Kemski.

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