Peavylotus' Rebuild of the KZ Cafe

A mini project I had with the coils.

This is the state I received the coils in. A bit dirty is all. So I cleaned them up with acetone.

partial view of them, more will come down the list.

Next, I addressed the dirty and gunky terminals

I put some new gold plated nuts on them with gold plated washers with some connectors in which I will solder to the main harness which I am constructing now.

This will give it a solid connection that I wont have to worry about.

After this I took notice of the mounts. The bolt and washers looked terrible. With a little washer modification I was able to clean it up a bit. This is what it looked like before modifying them.

This is the washer mod

And the washer mod result

More of the results. Just looks more purpose built rather than slapped together.



Next was the other side of the coil, This was a bit trickier with the plastic sleeve. So washer mods were extended!

This is the mod. Two more cuts

With two washers it becomes level with the plastic sleeve.

End result looks like this.

And this

This is how the whole setup turned out








The Dyna 2 Stage is pretty F'n sweet, I can't wait to get it all hooked up. This picture shows the perameters it controls.



Very happy with my ignition setup and am piecing the bike back together. More pictures to come, as I made much more progress this afternoon.

Got the engine back together. Next is to wire in the 2 Stage limiter, electro tach, the sweet accel coils, lights, horn and blinkers. That will be pretty fun. I made a bare bones harness before but now I am making pretty much a factory extensive harness so Itll be a tough one.

(Picture won't insert because I'm on mobile)

Not the best picture but it s where I'm at

looks great how much more do u have to do

lightitup wrote: looks great how much more do u have to do

Wireing harness, seat bracketry, exhaust and brakes as well as any quirks that come after she starts up. I do have to do valve shims because of tight tolerances but I plan to buy a new head during the summer so I'm putting it off.

I kicked it over with the sparkplugs in and the difference was night and day with the newly bored cylinders I'm so stoked for this

It looks so good so far.You are very talented.

Well, I have been moving slow but I am back on track with a new tool even. I have been talking about doing a video series on Youtube and well thats what I am doing now. I've decided to go ahead with the brake conversion and here is a video about the bracket and my CNC machine.

Cool.

Made a little holder for the electrics so they weren't bolted to where ever was available. I am so happy with the results. I pocket milled the reg/rec, cut an opening just big enough for the top section of the battery to fit flush (the body of the battery is 1mm wider that the head of the battery) and I mad a hole for the rev limiter to be inserted from behind.

The little slot next to the rev limiter wire was for the wires to run out of the bottom but I cut it on the wrong side, though I like the wires from the top because they would interfere with the mounting brackets on rev limiter. I think it calls for the famous word of bob ross 'We don't make mistakes, it's just a little happy accident'. haha

looks sweet!
love the bob ross reference,got a chuckel outta that.

will the plastic take the heat generated by the ignitor?

leon