1980 KZ440 project build...err... rebuild...

I starting getting parts today, so will be working on my three day weekend on more of the project.

Any decent places to buy the jets from? 1 set looks brad new, the other is plugged. I should get pictures up tomorrow. Just using the camera instead of the phone. SD cards are easier to use then the phone hook up software anymore.

Anyhow, I am still going to try to clean the jets, and see where I can go from there.

CPLSeraphim wrote: I starting getting parts today, so will be working on my three day weekend on more of the project.

Any decent places to buy the jets from? 1 set looks brad new, the other is plugged.

I have bought jets from Dime City Cycles ( www.dimecitycycles.com ); they have parts for Keihin and Mikuni carbs.

I should get pictures up tomorrow. Just using the camera instead of the phone. SD cards are easier to use then the phone hook up software anymore.

I usually just email the pic to myself from the phone. That won't work as well if you have a lot of pictures to transfer, but for one or two it's convenient.

Yeah, I usually do that. I just took a lot of pictures at once. I may just do that tonight to get it going. Thanks for the link. I have to look at the price their. I think I should be able to clean them. But it's nice to know just in case.

Alrighty, so I got the start rebuilt a while ago. Yesterday, before putting the new coil in, I shortened the old wires because I noticed that maybe the screws in the boots weren't making contact with the wire in the plug wires. I did this, and determined the coil was bad. Well, I swapped out the coil, and went to test, and my starter won't turn over...

I also noticed my lights would be on, but not the head light... I put the bike on the charger over night to see if the battery was just that low (I knew it was getting kinda low since I was turning it over for a while, over the course of the last week, and not charging it... oops)

I'll find out today, when it gets just a little warmer. Figured it was worth noting.

So, I found a loose wire that was the problem with the headlight. easy fix, probably from when I was installing the new coil. However, the starter is just clicking. I just rebuilt the starter, and it was turning over just find... then it stopped. I thought maybe it was wiring since I just put in the coil, but I found nothing. I think it stopped before I switched the coil anyhow. So, I hear the starter relay clicking, and when I touch the starter, the back end, it gets warm when I am trying to start it... Does anyone have any suggestions, or am I going to have to rebuild the starter... again?

Measure voltage to the starter.


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Ok, so when I have the positive on the starters bolt, and the black on the body of the starter, and I try to start it, my voltage drops down to 5 V... Same reading I get on my battery when I hit the start...

My voltage on the starter solenoid goes from normal to like .25 V when start button pressed...

I am assuming that, by the battery and starter dropping to 5 V, the battery is bad? But that is a brand new battery...

Have you been keeping the battery charged while you are working on getting it started?


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Hello CPLSeraphim
It looks like your starter motor was blocked.
Can you turn the starter motor by hand (if removed from the engine)
If the starter motor does not turn the commutator will short cut.
This will cause your voltage drop. This will end up in a burned up stator winding.
Have you cleaned the commutator with a fine sandpaper or file? the gap between can be short cut!!!



Are the brushes in good shape?

Michael

Nebr-Rex: I have been keeping the battery charged with a trickle charger. reading a good 12.6 ish before trying to start.

Scirocco: I could not move the starter the last time until after I rebuilt it. When I rebuilt it, it spun nice, and would turn the bike over. It was cleaned, but I did not sand it. there were no gaps being shorted at that point. I will be removing the starter tomorrow, and will take a look, and try to post pictures then, at least of the starter.

It was a lot cleaner then the one in your pictures, just had a lot of black dust on there. I am worried that the magnet came loose again, and might be stuck to the commutator. That would make sense, I suppose, on why it isn't turning, and a big magnet stuck on would surely short it out.

If that is the case, what can I use to glue the magnet down that will secure it?

Will update during teardown of starter:

I pulled it, and it does not turn by hand, and when power is applied, it does not start.

and I found the problem....


The magnet that wasn't secure shattered inside the starter... looks like I'll be buying a new starter.

Alright, so right now I have a new ignition coil, new wire ends, new spark plugs, new starter, and... no spark still. I am going to have to trace the wires, I suppose. Getting ready to put the new chain and sprockets on. I have to try to figure out the spark thing though, I mean, it would seen that it would have to be a bad wire or connection somewhere if everything else is new and the fuses are good.