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Author Topic: KZ 250 C "Blueberry"  (Read 3852 times)

Offline dray

  • Posts: 26
Re: KZ 250 C "Blueberry"
« Reply #10 on: Dec 10, 2017, 11:54:09 »
Did more work on the bike, not so much free time around this time of year with work/family/friends/life but I'm hoping to plow through and hopefully get this project done by mid January.
Putting the bike back together has proven not so hard especially with the help of all the photos I took before i pulled it apart.
Have made some silly mistakes and have a few mental melt-downs. spent 2 hours Going over and over again on the electrics as I wasn't getting current.
I played around with the multimeter, put the battery on trickle charge, checked connectors, replaced old ones. finally after tracing it back to the starter solenoid I wiggled the main fuse line and bam! on comes the lights. Contact was in but wasn't tight enough. sigh...
Wiring for the lights, speedo, tacho and indicators on the front end have been done, some bullet connectors grouped and replaced with plug connectors.
Looking to replace the old combo handle bar switches with new ones but hit a slight hurdle. New switches are cheap online no brands with extra wires, took me a while to open them up and work out which were redundant and which I should splice together. hopefully later today I can get it sorted and matched up to the KZ's wiring harness.
On another note, because my forks are heavily scarred from rust, I've been trying to think of a (cheap) way to cover up and protect them.
I had some carbon fibre contact wrap which could have done the job but it looks out of place. I'll go get some flat black contact instead. I'd be happy to hear any suggestions on alternatives. I know I can get them re-chromed but it's not a priority right now.
Cheers

Offline teazer

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Re: KZ 250 C "Blueberry"
« Reply #11 on: Dec 10, 2017, 17:22:21 »
The spare 2 go to the brake switch so they tie in to the loom.  Older bikes tended to have those wires on their own.

Offline cbrianroll

  • Posts: 212
Re: KZ 250 C "Blueberry"
« Reply #12 on: Dec 11, 2017, 02:24:07 »
I used electrical shrink tubing on my forks. I think from Amazon. Had to cut them off when I blew a seal, need to reorder. What a coincidence....mines a kz550.

Offline teazer

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Offline dray

  • Posts: 26
Re: KZ 250 C "Blueberry"
« Reply #14 on: Dec 12, 2017, 10:31:20 »
hahah I'm kicking myself for not thinking of that! I guess it shines a light on my lack of experience but lucky for me I'm in the right place  8)
These are great ideas, the shrink wrap is quick and easy, the chrome tube is brilliant, I just have to find a matching size of 36mm / 1.4 inch dia. I looked at dark chrome paint but i'm worried it will scratch easy so that idea is out.
I spent my free time today working on all the electrics, cut, crimp, solder, shrink wrap, replacing old connectors, splicing, testing switches etc.
I reworked the front brake light switch into the HB switch block(cheers Teazer). Works a treat now and helps tidy up the front end.
I sorted out the seat tray for the electrics, now most components are neatly housed, I bolted the new fuse box but decided to use velcro tape for the flasher and cdi. I figure that would be more than sufficient as they are not heavy items and can't fall out of the tray, I want to avoid drilling holes in the tray where possible.
So all was good, I'd finished cleaning up the wiring harness, weaved it back into the frame, connected everything up, I was all set to pat myself on the back for a job well done and head inside for dinner. I turned the bike on and ... some things didn't work.
Lights mostly. As panic mode started to set in I went over all the connections checking for lose wires but somewhere along the line I had maybe reversed some earth wires or something like that. As a result switches were jumbled up.
As you can imagine I was in a dark place for a while but I managed to recover some functionality but now I'm flying a little blind as the wiring diagram and previous switch blocks can only help so much.
I'm having to juggle between the switches and front end to get them to talk to each other. Fun fun.

Offline dray

  • Posts: 26
Re: KZ 250 C "Blueberry"
« Reply #15 on: Dec 13, 2017, 08:18:55 »
OK so all electrics are done! .... almost. I have an indicator problem. Rear indicators working fine. Front indicators not so much. So I have an electric riddle which I could use some help with.
Rear indicator voltage output is a healthy 12.54v
Front voltage Right side is 10.30v steady.
Front voltage left side is on a continuous  variable voltage from 4.5v up to 8v and back down again...
It seems the indicators for the front that I want to use won't accept anything but 12v.
I can attach cheap indicators to the front which work though rather weakly.
I though maybe I could try removing and bridging some resistors on the indicators I want, though I don't know which resistors to remove.
How to fix please.


Offline dray

  • Posts: 26
Re: KZ 250 C "Blueberry"
« Reply #16 on: Dec 15, 2017, 12:21:42 »
Reposting - Ok so I found and resolved the issue!
After discussions with some local electric moto wizards (picture if you will, long beards waving around soldering irons) I was given a few options involving transistors or alternatively (the path I took) instead of running everything in series, I could run an earth from the indicator to the common earth in parallel with the existing circuit!
i.e pos + > Indicator > odometer > common earth.  vs pos+ > indicator > common earth + odometer > common earth.
Once I wired up the second wires from both front indicators and connected them to the shared earth - boom - Merry Christmas.
So it would appear that these cheap odometers have high value ohm resistors in them to protect the 5mm LEDs and downgrade the voltage, problem with this is the output voltage - is not high enough for the indicators to fire up.
moral of the story - buy quality parts or waste time fixing cheap parts.
That completes the electric side of the bike for now. Later I want to introduce an LED voltage display into the seat tray and because I love LED's so much I plan to run some blue lights under the tank over the engine for that aesthetic look. Some folks might not like it but I think they're a fantastic invention.


Offline teazer

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Re: KZ 250 C "Blueberry"
« Reply #17 on: Dec 15, 2017, 16:42:24 »
Great progress.  Do not limit yourself to blue LEDs.  There are all sorts of colors and some that change color. Some will argue that they are the sign of the lowest form of style, but I like them precisely because of that.  They are in your face and fun - and they are only on when you want them on....

Offline dray

  • Posts: 26
Re: KZ 250 C "Blueberry"
« Reply #18 on: Dec 20, 2017, 09:13:21 »
Great progress.  Do not limit yourself to blue LEDs.  There are all sorts of colors and some that change color. Some will argue that they are the sign of the lowest form of style, but I like them precisely because of that.  They are in your face and fun - and they are only on when you want them on....
Totally with you on this, If I was king for a day I'd have LED's as a standard feature on all bikes. They look good (if tastefully done) and they help with safety.
I've got a plastic fantastic KLE650 with the full LED kit + remote. I'd sneak a photo of it on here but it's off topic.
Below however are the mods complete. LED lights and volt meter. I'm going with blue as it fits with the colour scheme. The tank and farings will be blue.
« Last Edit: Dec 20, 2017, 09:26:57 by dray »

Offline dray

  • Posts: 26
Re: KZ 250 C "Blueberry"
« Reply #19 on: Dec 20, 2017, 09:25:28 »
So another challenge has presented itself. Today I filled the engine with oil, attached the carb and turned it over. Turn over it can but won't idle.
Pulled the carb out and gave it another good scrub. The bike still turns over and putts away but as soon as i take my finger off the starter, the engine dies.
Throttle does work to a limited degree, I can get it to rev higher, sort of.
In all my efforts I think I killed the battery, I have a back up to use but I'll need to come up with some strategies.
I'll be getting some fresh fuel, the stuff I have has been sitting around for a month, I think it's still ok but I want to eliminate possibilities.
Spark is good, timing and compression not checked.
Jets, idle and air valve to spec. might do more tweaking but that's tricky without a basic idle.