KZ 440 Basketcase - AKA The "Pig"

Bruce - the factory connections wouldn't be crimp connectors, they would be bullet connections or plastic plugs.  The taped up crimp connection you show would have been added later.  And good for you using bullet type connectors to "correct" the harness.

sf4t7 wrote:

Bruce - the factory connections wouldn't be crimp connectors, they would be bullet connections or plastic plugs.  The taped up crimp connection you show would have been added later.  And good for you using bullet type connectors to "correct" the harness.

Scotty these "in loom" crimp connections are called "nodes" and every automotive manufacturer uses them throughout the OE wiring looms, There will be dozens of these in your bike's loom (and they become a point of failure if the tape is damaged and moisture can get in to corrode the connection) The below illustration shows where these are used and how they are illustrated on the wiring diagram (nobody ever tells you "exactly" where they are !!)

 

Thanks for the correction Guy, my bad.  My harness is in good shape (tape covering it is still intact) so I never noticed the crimp connectors.  Electrical is not my best skill, so a little knowledge can sometimes lead to the wrong place.   

Still waiting on bullet connectors but I did re-wrap the loose node wires. 

Now that the wiring is routed correctly I realized the airbox actually fits. I spent some time creating a filter holder for the airbox. Being self-taught on Fusion 360 the design could be cleaner but it looks like it might work. I was going to get some of the foam filter material and cut it to fit. I still need to line up some mounting screws and a small bracket to attach it to the airbox. 

I am looking forward to trying it out but need more parts to show up. 

Excellent.

That is some excellent design on that filter box. Nice!

Quick update. 

I was able to fix some of the bad wiring, added some addition length to others, and now the loom sits in the frame nicely. 

The new flanges work so I reinstalled the pipes after a bit of polishing. 

Airbox and new 3d printed filter holder fit perfectly. 

I figured I had to at least try to start it. Turn key, left handlebar switch clicks, dead starter button. Remove all left switch connections,  no click when starter is pushed. 

so clearly I have a short somewhere. I will start going through it tomorrow and try to follow the wiring diagram as well. 

Oh well….

Looking good! You should sell that airbox file on ebay. 

So I spent a week stripping the front wheel of the awful silver rattle can, then did the etching primer, wheel paint and matte clear coat (Dupli Color all).  Today I tried putting the tire on. I bought some Shinko 230’s hoping they would be a decent tire. Obviously being a cruise tire they are pretty stiff. 

I tired the zip tie trick that I saw on line but all I managed to do is scratch up the rims everywhere there was a zip tie. So I started again the old way, got one side on, slid in the tube and fought like hell to get the other side on. After remembering how to do it from many years ago it was not too bad, but the rim paint took a beating. Aired it up only to have pinched the tube. Crap. Did a real mangle job on the paint taking the tire back off because I was pissed.  Now I feel like I am back to square one. 

The wheel before. 

Trying to get this project moving forward. 

I am just about done with paint so hopefully the reassembly will start next week. 

Seeing the KZ that was just posted makes me wish I had better skills. But again, this is my first real attempt. (maybe last as well…)

 

Every step forwards is progress 

Just caught up with this thread.  Buy enough used bikes and even the most educated bike buyer will buy a turd every now and then. I have bought my share and then some. 

That tank… legendary.

That is most certainly not a weld on the head stud as the stud is steel and the head aluminum. it is possible to solder these dissimilar metals but that is pretty nuanced and not widely available to the general public. I would Bet it is jb weld. If they did it right it’s actually a perfectly fine fix for this, but not my first choice.

I’ll be following along. Keep up the posts

dunno if you bought a tank already. But I seem to remember someone doing a tank swap here.