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

so, for the mean time, I am going to wrap my exhaust. It is rusty, and until I get a new exhaust, I am just going to wrap the one I have. I am also working on trying to figure out about a no spark issue. I bought new plugs, but they aren't the same, and my plugs are kind of worn out... Going to test in the lawn mower to see if it is the plugs themselves or not.

CPLSeraphim wrote: I have some slack in my chain I need to take care of. I may just get a new chain since this one has a ton of gunk and crapped grease all through it. I may try doing a good clean-up of the chain if I can adjust it enough. I can almost pinch the chain together. Scares me that the PO was riding it like that...

If you replace the chain, you'll want to replace the sprockets, too. A new chain on old sprockets will wear out prematurely; you'll get the best life out of all the components if you replace them as a set.

Sprockets are pretty inexpensive, so why not?

Nerdy is absolutely correct ! Take his advice and replace the chain and both sprockets as a set, otherwise the old sprockets will prematurely kill the new chain. Ed

well, I guess that makes sense. I didn't even think about that.

Real quick question, are these bikes supposed to have a fuse box? I ask because everything is hardwired, and I don't remember from my older KZ's. its been too many years.

There should be a small fuse box probably with 3 fuses much like that on the KZ650. On my KZ650-C1 it is under the right side cover. Here's a pic of it. Ed

Thanks, I'll go look in a second. Another issue, which could be a good sign, sort of. My engine turns over, no matter the position of the kill switch... That, and my starter got stuck once, and even removing the key didn't stop it. only happened once, so far. however, looks like I will be replacing the switch.

The kill switch in the OFF position cuts the ignition circuit, but the starter circuit still works (of course, the bike won't start though). This is normal. Ed

10-4... that is all and good then. BTW, found that fuse box... she be little. 3 fuses, main, front and tail. easy enough.

I just checked for spark.... nothing. nothing from the wires... which leaves me guessing at where to next? The igniter? Gotta test it first... those are kinda pricey. Off to youtube to check testing

Just checked the points plate. All seems well in there. looks real nice and clean, good clearance and everything.

Still figuring which part needs replaced, got to be the ignition coil, I suppose. Also, going over the wiring a 30th time to makle sure there isn't just a bad connection.

Just ordered an ignition coil. everything will be here in a few days, hopefully I will have this up and running before I get the title in the mail...

650ed wrote: Nerdy is absolutely correct !

Bet you never thought you would find yourself saying that particular sentence. :laugh: :laugh: :laugh:

Actually I have a great deal of respect for you and your contributions to this site. Ed

650ed wrote: Actually I have a great deal of respect for you and your contributions to this site. Ed

Much appreciated, thank you - and likewise.

I just meant that it's a combination of words that doesn't normally occur in nature. :laugh: