82' KZ440 Cafe' Brat Build: Carb tuning & exhaust fly by!
- Thread starter M.B Co
- Start date
M.B Co
Coast to Coast
Re: 82' KZ440 Brat'Cafe'?: Wiring, seat, final assembly
Good to hear. I didn't mind the added weight, next tires I hope to upgrade to new wheels of some sort. Maybe 18's all around or go with a wider spoked rim.
Started my wiring diagram. I am starting with updating the stock diagram so you can actually read it. All colors and "wires" will be updated.
Then I will slowly erase/remove items that are not being used and add new color's for the new items ie: controls, regulator/rectifier, fuse box
Example: Stock not finished yet
Updated Wiring Diagram Stock by MBCo, on Flickr
Good to hear. I didn't mind the added weight, next tires I hope to upgrade to new wheels of some sort. Maybe 18's all around or go with a wider spoked rim.
Started my wiring diagram. I am starting with updating the stock diagram so you can actually read it. All colors and "wires" will be updated.
Then I will slowly erase/remove items that are not being used and add new color's for the new items ie: controls, regulator/rectifier, fuse box
Example: Stock not finished yet
Updated Wiring Diagram Stock by MBCo, on Flickr
Re: Re: 82' KZ440 Brat'Cafe'?: Wiring, seat, final assembly
New tubes. Every time the tire comes off, always. They're five bucks and your life depends on 'em.
Doogie said:Hey man random question... did you have to have tubes with your new tires? And what type of valve stems are you running?
I have been trying to get my new tires mounted and the stealership is trying to tell/sell me new tubes.
New tubes. Every time the tire comes off, always. They're five bucks and your life depends on 'em.
M.B Co
Coast to Coast
Re: Re: 82' KZ440 Brat'Cafe'?: Wiring, seat, final assembly
The rims were designed to have tubes. I would re-install them IMO. But not sure the pros/cons of not running them on this style rim.
Keep in mind that the diagram is not finished. If more requests come in I may make some for people.
Rich Ard said:
The rims were designed to have tubes. I would re-install them IMO. But not sure the pros/cons of not running them on this style rim.
Doogie said:
Keep in mind that the diagram is not finished. If more requests come in I may make some for people.
M.B Co
Coast to Coast
Re: 82' KZ440 Brat'Cafe'?: Wiring, seat, final assembly
Also made me a diagram for MotionPro to go off of for my new cables.
Some of their requirements are confusing, I have to change a few measurements around
Clutch Cable Diagram by MBCo, on Flickr
How I plan to route the new clutch cable. I'll be getting some of those Stainless Straps from DCC to hold everything nice and tidy
Untitled by MBCo, on Flickr
Untitled by MBCo, on Flickr
Untitled by MBCo, on Flickr
Untitled by MBCo, on Flickr
Untitled by MBCo, on Flickr
Also made me a diagram for MotionPro to go off of for my new cables.
Some of their requirements are confusing, I have to change a few measurements around
Clutch Cable Diagram by MBCo, on Flickr
How I plan to route the new clutch cable. I'll be getting some of those Stainless Straps from DCC to hold everything nice and tidy
Untitled by MBCo, on Flickr
Untitled by MBCo, on Flickr
Untitled by MBCo, on Flickr
Untitled by MBCo, on Flickr
Untitled by MBCo, on Flickr
goochwarmer
Been Around the Block
Re: 82' KZ440 Brat'Cafe'?: Wiring, seat, final assembly, cables
How does the front end feel with just the support bracket instead of the whole fender? I've got the 550 and the front fender bothers the crap outta me, but deleting all together is a bad idea. I like the way yours turned out!!
How does the front end feel with just the support bracket instead of the whole fender? I've got the 550 and the front fender bothers the crap outta me, but deleting all together is a bad idea. I like the way yours turned out!!
County Fair
New Member
Re: 82' KZ440 Brat'Cafe'?: Wiring, seat, final assembly, cables
The bike is looking great!!
The bike is looking great!!
M.B Co
Coast to Coast
Re: 82' KZ440 Brat'Cafe'?: Wiring, seat, final assembly, cables
Got to work on it a bit this weekend. Not much done, but it's progress.
Seat pan cut out and bent to match the frame. Still need to trim the edges, front and round the rear the match the radius of the rear hoop. Attached by bolts and wing nuts. I'll take some pictures of those. Pan is thick 12g aluminum.
Untitled by MBCo, on Flickr
Untitled by MBCo, on Flickr
Untitled by MBCo, on Flickr
Untitled by MBCo, on Flickr
Welded on my 2-1 collector. Pipes are centered under the bike, and it does remove rather easily as an assembly. Takes some moving around though. Still working on muffler or tip options. I've changed my original plan.
Untitled by MBCo, on Flickr
Untitled by MBCo, on Flickr
FINALLY started wiring...for real. Torn down the entire harness, labeled everything, starting adding connections, shortening wires, heat shrink terminals etc...
Couldn't find a lighter, had to use matches.... ;D
Untitled by MBCo, on Flickr
Untitled by MBCo, on Flickr
Untitled by MBCo, on Flickr
Got to work on it a bit this weekend. Not much done, but it's progress.
Seat pan cut out and bent to match the frame. Still need to trim the edges, front and round the rear the match the radius of the rear hoop. Attached by bolts and wing nuts. I'll take some pictures of those. Pan is thick 12g aluminum.
Untitled by MBCo, on Flickr
Untitled by MBCo, on Flickr
Untitled by MBCo, on Flickr
Untitled by MBCo, on Flickr
Welded on my 2-1 collector. Pipes are centered under the bike, and it does remove rather easily as an assembly. Takes some moving around though. Still working on muffler or tip options. I've changed my original plan.
Untitled by MBCo, on Flickr
Untitled by MBCo, on Flickr
FINALLY started wiring...for real. Torn down the entire harness, labeled everything, starting adding connections, shortening wires, heat shrink terminals etc...
Couldn't find a lighter, had to use matches.... ;D
Untitled by MBCo, on Flickr
Untitled by MBCo, on Flickr
Untitled by MBCo, on Flickr
M.B Co
Coast to Coast
Re: 82' KZ440 Brat'Cafe'?: Wiring, seat, final assembly, cables
Stopped by my local moto shop and picked up some LED turn signals. Getting ready to order a new MotionPro throttle tube. The plastic one I got from DCC is junk. Oh well, $12 wasted.
Getting pissed at my welder, had my box for over a MONTH! Still not done, told them I want to pick it up asap. I'll take it to Cafe Racer downtown Kansas City. Give them boys some work.
Stopped by my local moto shop and picked up some LED turn signals. Getting ready to order a new MotionPro throttle tube. The plastic one I got from DCC is junk. Oh well, $12 wasted.
Getting pissed at my welder, had my box for over a MONTH! Still not done, told them I want to pick it up asap. I'll take it to Cafe Racer downtown Kansas City. Give them boys some work.
Doogie
Been Around the Block
Re: 82' KZ440 Brat'Cafe'?: Wiring, seat, final assembly, cables
Great. I just realized I actually bought the same throttle assembly from DCC. The reviews were not terrible for the price. Did yours fail? I'm not really liking the way the grip itself feels anyhow.
Bike is looking good though. Any ideas or progress on the seat?
M.B Co said:
Great. I just realized I actually bought the same throttle assembly from DCC. The reviews were not terrible for the price. Did yours fail? I'm not really liking the way the grip itself feels anyhow.
Bike is looking good though. Any ideas or progress on the seat?
M.B Co
Coast to Coast
Re: 82' KZ440 Brat'Cafe'?: Wiring, seat, final assembly, cables
One reason why I got it. Inexpensive, good reviews etc...It doesn't feel very smooth to me. And I don't like the fact that it doesn't have metal for the adjusting area. Seems like over time it will give out and break. So I've ordered an aluminum motion pro one.
No real progress on the seat. Still need material. Thinking of going with a high quality vinyl. Wrapping it myself. Attaching it to the pan with small self tapping screws with washers. Good idea?
I did slide one of my foam grips over it and made a huge difference. I'll be using the same grips on my new throttle tube.
Untitled by MBCo, on Flickr
New clean lens LED Signals. SUPER bright. And they will match my clear lens integrated LED tail/stop/turn
Untitled by MBCo, on Flickr
And of course how she's been sitting for months......
Untitled by MBCo, on Flickr
Doogie said:
One reason why I got it. Inexpensive, good reviews etc...It doesn't feel very smooth to me. And I don't like the fact that it doesn't have metal for the adjusting area. Seems like over time it will give out and break. So I've ordered an aluminum motion pro one.
No real progress on the seat. Still need material. Thinking of going with a high quality vinyl. Wrapping it myself. Attaching it to the pan with small self tapping screws with washers. Good idea?
I did slide one of my foam grips over it and made a huge difference. I'll be using the same grips on my new throttle tube.
Untitled by MBCo, on Flickr
New clean lens LED Signals. SUPER bright. And they will match my clear lens integrated LED tail/stop/turn
Untitled by MBCo, on Flickr
And of course how she's been sitting for months......
Untitled by MBCo, on Flickr
Doogie
Been Around the Block
Re: 82' KZ440 Brat'Cafe'?: Wiring, seat, final assembly, cables
I can definitely see that nylon/plastic piece snapping under some hard stress but I guess only time will tell that one.
I went to Joann's fabric store and got cut offs of high density, closed cell foam in one inch and two inch thicknesses for less than 10-12 bucks. I also bought a yard of black marine vinyl. Not my favorite material but it will definitely do for now. Probably spent around $18 total with an internet coupon. I m planning to attach it to my fiberglass seat pan with staples and contact cement. I think self-tappers would be fine but you would want to put some grommets or dished washers there so the material doesn't rip through when you stretch it.
Is your seat pan going to be removable? You could drill a bunch of holes around the edge and sew/thread the cover onto the pan with thick leather strips or something of the like. Might be a little too Harley but it wouldn't be seen. Just a thought.
I can definitely see that nylon/plastic piece snapping under some hard stress but I guess only time will tell that one.
I went to Joann's fabric store and got cut offs of high density, closed cell foam in one inch and two inch thicknesses for less than 10-12 bucks. I also bought a yard of black marine vinyl. Not my favorite material but it will definitely do for now. Probably spent around $18 total with an internet coupon. I m planning to attach it to my fiberglass seat pan with staples and contact cement. I think self-tappers would be fine but you would want to put some grommets or dished washers there so the material doesn't rip through when you stretch it.
Is your seat pan going to be removable? You could drill a bunch of holes around the edge and sew/thread the cover onto the pan with thick leather strips or something of the like. Might be a little too Harley but it wouldn't be seen. Just a thought.
M.B Co
Coast to Coast
Re: 82' KZ440 Brat'Cafe'?: Wiring, seat, final assembly, cables
Ya, it's removable. 2 wing nuts to attach it in the middle. You can see the bolt heads in the previous photo's. I haven't taken detail shots of it yet.
I have a perfect idea for the screws and fabric. At work we have these special button heads made for attaching screws to fabric. It's made out of abs plastic and it will distribute the pressure evenly. I'll post pictures shortly.
Doogie said:
Ya, it's removable. 2 wing nuts to attach it in the middle. You can see the bolt heads in the previous photo's. I haven't taken detail shots of it yet.
I have a perfect idea for the screws and fabric. At work we have these special button heads made for attaching screws to fabric. It's made out of abs plastic and it will distribute the pressure evenly. I'll post pictures shortly.
M.B Co
Coast to Coast
Re: 82' KZ440 Brat'Cafe'?: Wiring, seat, final assembly, cables
Ugh. Spent several hours wiring last night. Cut, strip, solder, crimp, heat shrink over and over.
I've learned that older motorcycle wiring is horrible. Make a simple damn circuit. Not everything needs 3x the wiring in the same circuit!
Detailed photo's of how I mounted my seat pan
Untitled by MBCo, on Flickr
Ugh. Spent several hours wiring last night. Cut, strip, solder, crimp, heat shrink over and over.
I've learned that older motorcycle wiring is horrible. Make a simple damn circuit. Not everything needs 3x the wiring in the same circuit!
Detailed photo's of how I mounted my seat pan
Untitled by MBCo, on Flickr
M.B Co
Coast to Coast
Re: 82' KZ440 Brat'Cafe'?: Wiring, seat, final assembly, cables
I'm getting new ones made by MotionPro. Already got my new clutch cable. Waiting on tube and new cable with ends that work with the new tube and new fittings to match the carb end.
I got this Push/Pull one
Thank you, means a lot. Been a slow build for sure. But not too worried about it. My dad has been fighting lung cancer that has spread 5 times this year. Not much time left....thus the reason the slow progress of the build.
Doogie said:
I'm getting new ones made by MotionPro. Already got my new clutch cable. Waiting on tube and new cable with ends that work with the new tube and new fittings to match the carb end.
I got this Push/Pull one
Gordy said:
Thank you, means a lot. Been a slow build for sure. But not too worried about it. My dad has been fighting lung cancer that has spread 5 times this year. Not much time left....thus the reason the slow progress of the build.
