KZed Police bike

This afternoon I installed Otakar's HID front headlamp kit. I am pleased overall with the setup, but I was hoping for more out of the "city light" led. I will update tomorrow after voltage/amperage tests. I couldn't run the bike after install due to a possible leak from the vent/overflow assembly under the tank. There has been an odor of gas over the last week that I couldn't pinpoint. When I removed the tank to run the wires to the battery, I saw some gas on the backbone and some seepage

On to the kit:


What is included


Close up of the new light with the LED city light at the bottom (left in the pic)


Stock headlamp mount cup




After removing enough material to slide the lamp into place. The LED protruded far enough to block easy insertion and now fits into the large slot in the bottom of the cup


The light installed. I will have to put a bead of clear silicone to keep the light in position. The lamp will rotate without the bead around the outside edge of the mount ring (not the outer trim ring)

I then ran the rest of the wiring and mounted the ballast.


Close up of the new lamp and LED


The ballast mounted on the inside of the fairing on the left inner side, the supplied double sided foam wouldn't hold the ballast against the unfinished fairing. I went with 3M trim tape instead


I ran the direct to battery wires through the grommet access plug which allows for access to the fairing reflector


Light on Hi-beam (city light LED only)


HID Xenon light on Lo-beam


HID light only, not the best pic or background


Top shot of the LED only


Top shot of the HID only

Overall I am very happy. The install was a breeze other than the cup having to be notched and the tank removal to run the wires

Total time: 1 hour

I finally got a chance to ride the bike today and see how the new headlight works in the daytime vs other vehicles and how the charging system would be affected.

Verdict: Excellent

Visibility: Very good. It shows up mucho better than the old halogen around town and on the highway. I feel much safer.

Energy consumption: Very Good. It draws less power than the old light. Previously, I had 2 greens with no light, 1 green with the halogen on, and no greens with the brakes and halogen on

Now, 2 greens with the HID on, with one of them flickering at idle with brakes on.

Draw is around .7 volts. Normal is 14.3-14.5 @ 4000 rpm, HID drops it to 13.5+

I can live with that

Thanks again to Otakar!!

Finally pulled the trigger on a new exhaust system. MAC Exhaust from DennisKirk.com, part number #44444, black header and collector with chrome canister www.denniskirk.com/mac/4-into-1-black-he...p44438.prd/44444.sku














Worst part was having to remove the crash bar to fit the new header. Test ride showed strong power throughout the range with pronounced crackle and pop during off throttle engine braking. The carbs are stock rebuilt/reconditioned units from oldskoolcarbs (ebay) using 125 mains. I will finish installing the 127.5 mains this afternoon and report back.

System was well put together and will work on any 82-06 KZ-Police (contrary to what Denniskirk says). Saddlebags are unaffected and now I have much more room to access the oil drain plug and filter. The center stand uses a bracket that the system provides, and I used clear silicone adhesive to adhere the rubber bump stop from the stock system to the bracket (blue masking tape in last pic). Can't wait to ride it again today post jet swap.

So, the jets have been swapped and while I was at it, I decided to finally replace the leaky valve cover gasket, clean up some wiring, clean up some parts, and replace the fork oil


prior to blasting with aluminum oxide

post blasting

Baking in the oven for 30 minutes at 170 degrees

Primered

I also had a lot of leaking and blowby from my American Classix oil cooler adapter: I decided to replace the rubber lines and Zephyr oil cooler with real fittings and hoses

new -6an fittings, also shown is the crankcase breather I blasted and painted, I also modded the airbox by sealing the lower hole and running tubing to the upper hole for case venting

Another view, in the second pic. the lines are running on the right side, underneath and along the frame. Cooler is a -6an inlet and outlet from Earl's. Everything was purchased through Summit Racing. Almost forgot, I had to get two -6an to pipe fittings to attach the new hardware to the oil cooler adapter

Another view, showing the new crankcase breather assembly painted and with new vent hose to the upper airbox hole. The lower one has been sealed off

motorscot wrote: Another view, showing the new crankcase breather assembly painted and with new vent hose to the upper airbox hole. The lower one has been sealed off....

Hoping a carb vent hose hasn't been sealed off. :huh:

Good Fortune!

Patton wrote:

motorscot wrote: Another view, showing the new crankcase breather assembly painted and with new vent hose to the upper airbox hole. The lower one has been sealed off....

Hoping a carb vent hose hasn't been sealed off. :huh:

Good Fortune!

How so? I removed the EGR equipment. I only have 1 vacuum line attached for the carb to tank feed. If I screwed something up, please tell me

motorscot wrote:

Patton wrote:

motorscot wrote: Another view, showing the new crankcase breather assembly painted and with new vent hose to the upper airbox hole. The lower one has been sealed off....

Hoping a carb vent hose hasn't been sealed off. :huh:
Good Fortune!

How so? I removed the EGR equipment. I only have 1 vacuum line attached for the carb to tank feed. If I screwed something up, please tell me

Unused vacuum nipples should be sealed/capped/plugged.
Vent nipples should remain open to atmosphere.
Okay to run hose from crankcase vent into airbox, or catch-can, or open to atmosphere.

Good Fortune!