The build begins: 82' KZ440 Cafe

[6-Bolt2g]

Wow, so much attention to detail to get the final product.

[6-Bolt2g]

Got my new fuel filter and new clear hose. I'll have it going when I get off work. May be ready for a ride to work tomorrow.

ton up!

[6-Bolt2g]

Did some test riding yesterday. Fired right up, powerband is pretty darn good.

I just need to sync my carbs and adjust the float levels to the correct specs.

[Billy Mild]

Looks good. Let's get a ride going.

[Kyle H]

Really like those wheels.

[6-Bolt2g]

Originally Posted by Billy Mild

Looks good. Let's get a ride going.

Maybe this weekend pending. Didn't get a chance to set float heights last night. Will try for tonight or Saturday. Then I'll need a long test ride....may have to bring some tools

Originally Posted by Kyle H

Really like those wheels.

Thanks. I was going to have them PC'd but after much thought. It would be better to keep them the way they are. Plus mags are just darn cool. I started to polish all the aluminum on there, lips look preeeety shiny now.

[6-Bolt2g]

Still having some weird issues.

It runs great at idle and running through all the gears to 6th at every throttle position. No back fire or pops coming off throttle, plugs look like they should, little brown/gray.

When in 6th or any gear for a period of time it will bog down in RPM, no throttle response and slowly die. Then will very slow crank. Let it sit for awhile and it re-starts and it goes through the same process again.

Carps are sync'd. Reading 14-15 cmHg

Fuel level in the bowls is "estimated" from my manual but NOT set with a fuel level gauge. I am thinking this is my problem, may have it still too high and it's pulled way to much fuel. I tried draining some out but it ran terrible at idle.

I feel as if I am so close. Thing runs great.

[sleepysvt98]

Originally Posted by 6-Bolt2g

Still having some weird issues.

It runs great at idle and running through all the gears to 6th at every throttle position. No back fire or pops coming off throttle, plugs look like they should, little brown/gray.

When in 6th or any gear for a period of time it will bog down in RPM, no throttle response and slowly die. Then will very slow crank. Let it sit for awhile and it re-starts and it goes through the same process again.

Carps are sync'd. Reading 14-15 cmHg

Fuel level in the bowls is "estimated" from my manual but NOT set with a fuel level gauge. I am thinking this is my problem, may have it still too high and it's pulled way to much fuel. I tried draining some out but it ran terrible at idle.

I feel as if I am so close. Thing runs great.

Hope you get the bugs figured out pal, I'm ready to ride!

[BluBeaSSt]

Originally Posted by sleepysvt98

Hope you get the bugs figured out pal, I'm ready to ride!

What did ya get?

[Billy Mild]

Originally Posted by 6-Bolt2g

Still having some weird issues.

It runs great at idle and running through all the gears to 6th at every throttle position. No back fire or pops coming off throttle, plugs look like they should, little brown/gray.

When in 6th or any gear for a period of time it will bog down in RPM, no throttle response and slowly die. Then will very slow crank. Let it sit for awhile and it re-starts and it goes through the same process again.

Carps are sync'd. Reading 14-15 cmHg

Fuel level in the bowls is "estimated" from my manual but NOT set with a fuel level gauge. I am thinking this is my problem, may have it still too high and it's pulled way to much fuel. I tried draining some out but it ran terrible at idle.

I feel as if I am so close. Thing runs great.

It sounds like your float height might be a little off. You might want check that. Do you have spark after the bike dies? You might have an eletrical issue or dying coil as well.

Do you have points or a CDI ignition?

[6-Bolt2g]

Originally Posted by Billy Mild

It sounds like your float height might be a little off. You might want check that. Do you have spark after the bike dies? You might have an eletrical issue or dying coil as well.

Do you have points or a CDI ignition?

Still has spark after yes. But will check again if the problem occurs 1 more time.

The OE Manual sucks for setting the float height. I found a killer .pdf regarding CV carbs, great pictures and better description of what to do.

Once I get that figured out, I do have an electrical issue with my headlight. But I believe I got it figured out.

Points

[Billy Mild]

Originally Posted by 6-Bolt2g

Still has spark after yes. But will check again if the problem occurs 1 more time.

The OE Manual sucks for setting the float height. I found a killer .pdf regarding CV carbs, great pictures and better description of what to do.

Once I get that figured out, I do have an electrical issue with my headlight. But I believe I got it figured out.

Points

Are the points original? What about the condesor?

[6-Bolt2g]

Originally Posted by Billy Mild

Are the points original? What about the condesor?

Not sure about original. But replaced within the past 5 years. Now that I am thinking about it, I may just go through and replace everything while I am at it.

Should of just done it to begin with. Oh well, that's me trying to save a buck or two.

[6-Bolt2g]

Started to lean towards electrical issue. While fiddling with my idle last night rested my arm on the right side cover. The bracket for the clutch cable going into the case was smoking HOT. Not warm, but hot enough to burn yourself.

WTF is going on I thought. Bike barley even ran and got warm, no way that is from it running. Then noticed small arks where the end of the cable goes into the arm, then to the bracket, then to the case.

With the key on and when it is running, while pulling the clutch lever or messing with the end of the cable it arcs, causing the rest of the bike to loose voltage.

I kept thinking my battery was just getting low due to trying to crank it. But something is shorted out limiting the voltage to the starter and the rest of the bike keeping it from starting etc....

The right side case is one I did not split. So not sure what could cause that. All my ignition items look to be fine, nothing loose, broken etc..

I'm stumped. Looks like I'll be splitting that side of the engine for inspection and removing all my electrical



Looks like another month I won't be riding

[Billy Mild]

Originally Posted by 6-Bolt2g

Started to lean towards electrical issue. While fiddling with my idle last night rested my arm on the right side cover. The bracket for the clutch cable going into the case was smoking HOT. Not warm, but hot enough to burn yourself.

WTF is going on I thought. Bike barley even ran and got warm, no way that is from it running. Then noticed small arks where the end of the cable goes into the arm, then to the bracket, then to the case.

With the key on and when it is running, while pulling the clutch lever or messing with the end of the cable it arcs, causing the rest of the bike to loose voltage.

I kept thinking my battery was just getting low due to trying to crank it. But something is shorted out limiting the voltage to the starter and the rest of the bike keeping it from starting etc....

The right side case is one I did not split. So not sure what could cause that. All my ignition items look to be fine, nothing loose, broken etc..

I'm stumped. Looks like I'll be splitting that side of the engine for inspection and removing all my electrical



Looks like another month I won't be riding

It sounds like one of the wires for your alternator is shorting out maybe? Does your alternator sit in oil?

[6-Bolt2g]

Sounds like it. Not sure if it "sits" in oil, but I think it may be lubricated by it.

Still sitting in my garage. Have not touched it, I really want to ride but not too motivated to fix it.

Such a dilemma

Excuse the mess



Oh, forgot to show where exactly the arc or short is happening. Red box showed the location. But my alternator is on the left side, not the right....

[Pny Pwr]

GROUND

sounds to me as if your engine isnt grounded to the chassis very well and the cable is taking the "load" and playing ground strap. try grounding the chassis to the motor

[Pny Pwr]

ps. if the voltage regulator is mounted under the seat it sees chassis ground/battery ground but the alternator is on the motor and sees motor ground. the alternator may be at max output because of this and you could create a fire/burn out/over heat a few components.

[6-Bolt2g]

Originally Posted by Pny Pwr

GROUND

sounds to me as if your engine isnt grounded to the chassis very well and the cable is taking the "load" and playing ground strap. try grounding the chassis to the motor

Wiring didn't change much. All grounds were relocated to another part of the frame, but will check their connections again. Thanks for the input.

And yes, the Voltage Reg is mounted under the seat attached to a fabricated pan where everything is mounted. I see what you are saying about the ground.

[Pny Pwr]

Ground that pan to th motor and the chassis to. Ride that beast! (love the build)

[6-Bolt2g]

Didn't really spend much time on it over the weekend. While re-spraying my grill I thought I would throw some coats on the header pipes. Turned out pretty good IMO.





I may strip the paint off the header pipe clamps and polish those to gain some contrast so there is not so much black on black.

[BluBeaSSt]

Bad ass man

[Jefferson]

It sounds to me like you have several issues. Electrical is one, and I agree that the engine is not grounded to the frame. Make sure there is no paint underneath the ground strap. The running fine to running poorly to dying sounds like you have a fuel supply issue. The next time it happens open your gas cap and see if there is a large whoosh of air going in to the tank. You may have a plugged vent hole in the cap and thus you run out of fuel due to the vacuum being pulled on the tank. Also make sure your petcock is flowing sufficiently. Have you taken the petcock out of the tank? They have a mesh screen in the tank that may be plugged enough that fuel flows too slowly. What is happening is you are using the fuel out of the carbs faster than it is being put back in. When you let it sit the fuel slowly fills the carbs back up. Then again, do you have a vacuum petcock? If you have a prime setting on the petcock see if it runs fine on that setting. It may be a petcock issue.

Jeff

[6-Bolt2g]

Originally Posted by Jefferson

It sounds to me like you have several issues. Electrical is one, and I agree that the engine is not grounded to the frame. Make sure there is no paint underneath the ground strap. The running fine to running poorly to dying sounds like you have a fuel supply issue. The next time it happens open your gas cap and see if there is a large whoosh of air going in to the tank. You may have a plugged vent hole in the cap and thus you run out of fuel due to the vacuum being pulled on the tank. Also make sure your petcock is flowing sufficiently. Have you taken the petcock out of the tank? They have a mesh screen in the tank that may be plugged enough that fuel flows too slowly. What is happening is you are using the fuel out of the carbs faster than it is being put back in. When you let it sit the fuel slowly fills the carbs back up. Then again, do you have a vacuum petcock? If you have a prime setting on the petcock see if it runs fine on that setting. It may be a petcock issue.

Jeff

• Only thing that has changed for the ground is to one side of the frame to the other. Clean ground, no paint, keeps the ground during all electrical functions

• It runs fine then immediately slows in RPM and dies

• I just installed brand new fuel lines and fuel filter. Clean flow of fuel also. The petcock has been removed not to long ago for inspection. Screen and everything else looked brand new and operational.

• I'll inspect the tank and vacumn. It is a vacumn petcock with a prime setting. I will try running it on that, what is the function for that setting? Will it hurt anything if it is ran on prime?

[Jefferson]

It won't hurt anything to run it on prime, but you should take it off prime before you park the bike or it could run all your gas out on the ground if a float would stick or something.

Jeff