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

Re: 82' KZ440 Cafe' Brat style- Pretty much done & ready to fire

Got all of the wiring done this weekend. Had some help from a friend and after staring at it for awhile we got it figured out.

Essentially my right side control acts as a master switch aka run/kill. Off position everything dead, turn to run powers a relay and my fuse box which I had to run jumpers to make all positions hot when activated. This turns on my ignition system, starting, lights etc.... push the start button and she turns over.

No key, no toggle just simple...

Just need to buy my Shorai battery.

Few more zip tires, loom it and attach to the frame

IMG_20140504_200807 by MBCo, on Flickr

IMG_20140504_200827 by MBCo, on Flickr
 
Re: 82' KZ440 Cafe' Brat style- Pretty much done & ready to fire

M.B Co said:
Essentially my right side control acts as a master switch aka run/kill. Off position everything dead, turn to run powers a relay and my fuse box which I had to run jumpers to make all positions hot when activated. This turns on my ignition system, starting, lights etc.... push the start button and she turns over.
Click to expand...

VERY clean and clever! 8)
 
Re: 82' KZ440 Cafe' Brat Build

Didn't get a Shorai as my local supplier stopped carrying them. Asked what they had that was comparable and mentioned WPS featherweight litium battery.

150CCA 9Ah, and smaller in size plus 2 year warranty. $99. If I am not impressed I'll return it and go with Shorai. Reviews are positive.


IMG_20140506_132844 by MBCo, on Flickr
 
Re: 82' KZ440 Cafe' Brat Build- so close! starter needs rebuilt

I read about cleaning them out and they work again. Seems like you cant catch a break.


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Re: 82' KZ440 Cafe' Brat Build- so close! starter needs rebuilt

Jrbrownie00 said:
I read about cleaning them out and they work again. Seems like you cant catch a break.


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Click to expand...

I'll get it torn apart tonight and see. Going to order a rebuild kit for it today. Always wondered why it cranked slow all these years, just thought it was normal lol
 
Re: 82' KZ440 Cafe' Brat Build- so close! starter needs rebuilt

Know how you feel man get one thing fixed and find another thing broken

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Re: 82' KZ440 Cafe' Brat Build- so close! starter needs rebuilt

too much feelz how i feelz about this

Took her apart and did a deep clean. After cleaning it worked as designed for a few test tries. Re-installed everything and it starts and turns over great for the 1st and 2nd time then it seems it just seizes up and hates life. So back apart it came. Brush kit on order so I should see it middle of next week.

Pictures after cleaning attempt

Oh, and it smells like rotting dead animal anus stuffed with wires coated in gear oil then lit on fire then extinguished with urine

IMG_20140508_201820 by MBCo, on Flickr

IMG_20140508_201800 by MBCo, on Flickr

IMG_20140508_201750 by MBCo, on Flickr

IMG_20140508_201736 by MBCo, on Flickr

IMG_20140508_201718 by MBCo, on Flickr
 
Re: 82' KZ440 Cafe' Brat Build- so close! starter needs rebuilt

Might be a good idea to take it to an auto alternator/starter specialty shop to have them check it out. What comes in the rebuild kit (in addition to brushes)? Bearings? How does the armature commutator look? A good shop can turn it down real quick.
 
Re: 82' KZ440 Cafe' Brat Build- so close! starter needs rebuilt

zap2504 said:
Might be a good idea to take it to an auto alternator/starter specialty shop to have them check it out. What comes in the rebuild kit (in addition to brushes)? Bearings? How does the armature commutator look? A good shop can turn it down real quick.
Click to expand...

That's a good idea. There is one near my office that I can take it to.

Rebuild kit comes with the brushes
(example: mine has 4 brushes, this shows 2)
DSC05289.jpg


Commutator doesn't look damaged just dirty and dark. Coils/winding's in same condition. It doesn't spin by hand at all, I cannot even turn it.
 
Re: 82' KZ440 Cafe' Brat Build- so close! starter needs rebuilt

That thing looks wet on the inside. Do you have a bad seal?
 
Re: 82' KZ440 Cafe' Brat Build- so close! starter needs rebuilt

fresh_c said:
That thing looks wet on the inside. Do you have a bad seal?
Click to expand...

It was wet inside. The starter valley was dry and the starter itself on the outside was dry. So all the "wetness" contained itself.
 
Re: 82' KZ440 Cafe' Brat Build- so close! starter needs rebuilt

M.B Co said:
Commutator doesn't look damaged just dirty and dark. Coils/winding's in same condition. It doesn't spin by hand at all, I cannot even turn it.
Click to expand...
Might just need new bearings; the commutator might be able to be cleaned up with emory paper. A good shop would know (and be able to source/replace bearings).
 
Re: 82' KZ440 Cafe' Brat Build- so close! starter needs rebuilt

Dropping it off at a local shop. Sounds like they have a quick turn around. So, possibly could have it back by the end of the work. if that's the case the bike will be complete this weekend. Also mounted my new super small battery underneath my seat.
 
Re: 82' KZ440 Cafe' Brat Build- so close! starter needs rebuilt

Just went ahead and got a new brush plate kit. Got it together last night and it's operational now. Time to throw it in tonight or tomorrow and fire her up!
 
Re: 82' KZ440 Cafe' Brat Build- so close! starter needs rebuilt

It runs! Fired up on the 3rd crank until the splash of gas ran out. I did see a small leak at one of the bowls for some reason.

Tomorrow I'll get a video and report and on how she runs.

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