82' KZ440 Cafe' Brat Build: Carb tuning & exhaust fly by!

[predawn sky]

Re: 82' KZ440 Brat'Cafe'?: Seat upholstered- ready for spring!

Yesterday I did some mod to my exhaust and when went to put them back on one of the studs broke

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[predawn sky]

Re: 82' KZ440 Brat'Cafe'?: Wiring, seat, final assembly, cables

Hey what bettery are you guys with KZ440's using?

I want to find the smallest possible, have been looking at these
http://shoraipower.com/lfx14a2-bs12-p66
http://www.ballisticparts.com/products/batteries/8cell.php

what do you take into consideration when thininking abot a battery?

I like the looks of the battery from ballisticparts

 

[M.B Co]

Re: 82' KZ440 Brat'Cafe'?: Seat upholstered- ready for spring!

Yesterday I did some mod to my exhaust and when went to put them back on one of the studs broke

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I take mine off frequently and that's one thing I fear.

I like the looks of the battery from ballisticparts

I would of ran one but the cost is up there. My smaller bikemaster agm unit will work just fine for my build.

Battery box will be done Monday.

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[Jrbrownie00]

Re: 82' KZ440 Brat'Cafe'?: Seat upholstered- ready for spring!

I take mine off frequently and that's one thing I fear.

I would of ran one but the cost is up there. My smaller bikemaster agm unit will work just fine for my build.

Battery box will be done Monday.

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Be very careful man, one of mine snapped inside the head. Had to drill it out and have to have it welded but for now it's being held in by one side and the other 6 studs.

The size of the battery makes it worth more money, is it worth the 140... Tough to justify but I sprung for it and it works well.

 

[jsnabbs]

Re: 82' KZ440 Brat'Cafe'?: Wiring, seat, final assembly, cables

I like the looks of the battery from ballisticparts

I went with the shorai, having a electrics tray welded up with a recess for the battery. should be picking the frame up from the fab shop in a week or so

 

[M.B Co]

Re: 82' KZ440 Brat'Cafe'?: Seat upholstered- ready for spring!

Yup. Another weekend goes by that I don't get any time to work on the bike. Busy busy, life happens.

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[M.B Co]

Re: 82' KZ440 Brat'Cafe'?: Seat upholstered- ready for spring!

Needed some sunshine.

Cables arrived. Battery box still at the fab shop, they called and the material I provided was too thin so they had to get new aluminum and match the dimensions. Hopefully I'll have it back tomorrow.

 

[Jrbrownie00]

Re: 82' KZ440 Brat'Cafe'?: Seat upholstered- ready for spring!

Looks like it really wants to be ridden man. Get that thing finished


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[combustioncafe]

Re: 82' KZ440 Brat'Cafe'?: Seat upholstered- ready for spring!

I just read your whole build from front to back. I wanted to thank you for the details you listed in your thread that have certainly saved me a ton of time and aggravation.

My cousin and I picked up an 81 440 LTD over the weekend, running with a spare motor for $550. We won't be rebuilding it until next winter, but just getting it running right for now. Your KZ is very similar to the direction we're wanting to go. Keep up the good work, and I hope you get to ride soon.

 

[M.B Co]

Re: 82' KZ440 Brat'Cafe'?: Seat upholstered- ready for spring!

Looks like it really wants to be ridden man. Get that thing finished

I know right, my anxiety and anticipation is killing me.

I just read your whole build from front to back. I wanted to thank you for the details you listed in your thread that have certainly saved me a ton of time and aggravation.

My cousin and I picked up an 81 440 LTD over the weekend, running with a spare motor for $550. We won't be rebuilding it until next winter, but just getting it running right for now. Your KZ is very similar to the direction we're wanting to go. Keep up the good work, and I hope you get to ride soon.

Thank you for the kind compliments. Being my first build on a relatively not so sought after bike and the lack of detailed builds I thought I would create one for others to use. At the end I'll describe what I did and items used with links. The build is pretty simple and budget friendly, which was my goal.

 

[M.B Co]

Re: 82' KZ440 Brat'Cafe'?: Seat upholstered- ready for spring!

Tig welded aluminum battery box is done picking it up on my lunch break. Pictures to follow shortly.

They ended up grinding the welds smooth which I didn't want. But oh well, it will work

 

[predawn sky]

Re: 82' KZ440 Brat'Cafe'?: Seat upholstered- ready for spring!

finely got my bike running again but without the mufflers, its a lot louder in real life

https://www.facebook.com/photo.php?v=10202761406230070&l=4257021561465062426

 

[M.B Co]

Re: 82' KZ440 Brat'Cafe'?: Seat upholstered- ready for spring!

Almost done with my wiring. I keep changing how I want to do things and it's getting tricky.

Pretty much not going to run a ignition switch key or toggle. Going to be ran off my right side control switching ground and power. So my run/kill acts as a master switch inline with a relay to my fuse box to give me switchable 12V.

I'll have a fully complete Google Drawing that I can share with anyone interested running a similar setup.

 

[M.B Co]

Re: 82' KZ440 Brat'Cafe'?: Seat upholstered- ready for spring!

Four hours later I have a much shorter throttle cable. Clutch should go quicker...... I hope

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[M.B Co]

Re: 82' KZ440 Brat'Cafe'?: Seat upholstered- ready for spring!

Pictures of the cable that I ended up re-doing. This time around took me no time.

My DIY solder pot worked perfect and they are super strong.

Untitled by MBCo, on Flickr

Untitled by MBCo, on Flickr

Untitled by MBCo, on Flickr

 

[Jrbrownie00]

Re: 82' KZ440 Brat'Cafe'?: Seat upholstered- ready for spring!

That's a great idea, elaborate for me... You made some sort of "pot", put the cable inside and filled the "pot" with solder?

 

[M.B Co]

Re: 82' KZ440 Brat'Cafe'?: Seat upholstered- ready for spring!

That's a great idea, elaborate for me... You made some sort of "pot", put the cable inside and filled the "pot" with solder?

Used an aluminum socket tool I didn't need
Cut up some silver solder, placed in "cup" of the tool
Laid my torch next to it heating it and the solder melts
Skim the top to get rid of the impurities
Get the cable and barrels clean and ready, apply flux
Slowly heat the barrel and cable
Dip and submerge cable and barrel in flux and leave it there for several seconds
Remove and cool with water

I pulled as hard I can with pliers and it didn't budge

I followed these threads for info

http://www.motorcycleforum.com/showthread.php?t=102449

http://roccitycafe.com/blog/diy-cables/

 

[Doogie]

Re: 82' KZ440 Brat'Cafe'?: Seat upholstered- ready for spring!

You can also drill a hole in a 2x piece of wood. One on the top about halfway down and one from the side to slide the cable through. You get the idea.

 

[M.B Co]

Re: 82' KZ440 Brat'Cafe'?: Seat upholstered- ready for spring!

Picked up a digital/electronic flasher relay for all the LED signals and a 30a 5-prong relay for my ignition setup. Hope to spend a couple hours tonight finalizing my wiring theory.

 

[M.B Co]

Re: 82' KZ440 Brat'Cafe'?: Seat upholstered- ready for spring!

My Master kill almost works. Now my starter button doesn't work.

How I feel

I

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