KZ440 LTD Cafe

Hi guys. I bought a cheap kz440 ltd with some bent exhaust valves. The previous owner was trying to do something to the engine and got the timing wrong and the pistons made contact with the valves.. I am bulding this bike on a low budget on because I became a dad for a baby girl in january so most of the money is going to diapers and baby stuff .
So far I got the engine running. I also sorted out the electrics it was a mess.. and had melted before and been fixed in a bad way. I think I found the melting problem, brown wire from the recrifier was not connected to anything. When the engine was running and wiring sorted I started disassembling the bike again and modifying the frame.
Now i am wondering does this bike really need a huge 12v 14ah battery? Would it work with 6Ah or do i need go lifepo4 to get a smaller battery and what size shoud this be then?

Nice job on the subframe... the drop seat and having to do that specific work is what keeps me overlooking the LTDs.... kudos.

Awesome. Enjoy the baby girl too. They change fast and there's no restoring them to original condition

I might need a new regulator rectifier, found a big crack in it and smells pretty burned... Is there any aftermarket ones that would fit or do I a have to get a original part? Finding a new original might be hard to come by in Finland

I think its done. Where can I find a replacement? Anything that would work on aliexpress? I Would get a used oem part from ebay but the shipping to finland can be quite expensive. Any suggestions?

I may know a place here in the Netherlands. I could check for you. Shipping from NL shouldn't be too bad.

Venderbroeck said:

I may know a place here in the Netherlands. I could check for you. Shipping from NL shouldn't be too bad.

Click to expand...

Got the new part today but i am having an issue with wiring..
Here is how I did the wiring
2 yellow ones goes to the alternator
Red white to the battery/starter solenoid +
Brown to + coming from ignition switch
My main concern is with the black wire thats supposed to be ground? When I connect the wires the black wire becomes positive 12.6 volts.
I dont want to melt down my new rectifier..
What am i doing wrong.

Judging by the wiring diagram:

-2x yellow to alternator
-red/white battery(+)
-brown to ign switch amongst other things
-black to ground / battery(-)

So what you did should be correct.
It could be normal that it shows 12.6 volt when disconnected, but I can't test it with mine.
I wouldn't run it without the ground connected though, you might get funky current paths inside the reg/rec.

Venderbroeck said:

Judging by the wiring diagram:

-2x yellow to alternator
-red/white battery(+)
-brown to ign switch amongst other things
-black to ground / battery(-)

So what you did should be correct.
It could be normal that it shows 12.6 volt when disconnected, but I can't test it with mine.
I wouldn't run it without the ground connected though, you might get funky current paths inside the reg/rec.

Click to expand...

The near battery voltage was normal ,got the info from a kz forum. The wiring is now almost done, just need to get a new headlight and sone ”warning lights”. I am trying to get the bike done before summer but I still have alot of things to do.

Nice job de-uglifying that ltd frame.

Slowly getting back together

Nice work on the subframe. How much did it change the geometry? Just curious.

Cant really say how much from the original because the shocks were not original. So i did not really take time to measure, however the rear shocks can be adjusted so we will have to see how it drives.

I have been doing some test rides with the bike and its seems to be working just fine. Only problem is that its smoking quite much when cold... it gets better when hot. I am thinking that I should have bored the cylinder and changed some oversized pistons. I am quite sure that the smoke/oil is not coming from the valve seals because the seals and guides are new.
The compression is just under the service limit.
So I am wondering what are the options for oversized piston kits? I have only found one on ebay 80€.