kz440 LTD kickstart

This is something I did 15 years ago. I believe it is well known that the kickstart internals from a 1979 kz400 fits the kz440. Yes, it just bolts right in



but that spring kept wanting to pop out of the hole so found something the right size (a piece of brake line I think) to make a sleeve that solved the problem


but make sure to use '79 parts. the gear I bought from ebay was listed with the '79 part number but clearly, with 23 teeth it is not a '79 and it doesn't mesh properly with the transmission gear. I only learned this when putting the case 1/2s together and they wouldn't close up because the gear didn't fit


The correct one (on the right) has 20 teeth


And for my bike, that was the easy part because mine is a late model year (1983) with the clutch actuator on the right hand side so it is not possible to use the side cover from a 400. So I had to use my side cover and there is no boss or support for the kicker shaft:



And it seems I am not allowed to fitt all my photis in one post so, continues next post...

... continuing:
so, make a template where the kicker shaft goes and mark it on a chunk of scrap aluminum, cut it out, clean it up and make it fit:





 

... continuing and finishing:
did some polishing while waiting for the correct 20 tooth gear to arrive


The kicker shaft support part I made I basically glued it on to the cover using RTV sliicone

And here it is still working (and not leaking oil) after 15 years and 50,000 km

 

Nicely done.

Cleaver adaptation!! Almost time to polish those covers again haha. I have a Friend with a belt drive 440 slated to bring it over shortly. I know those drive belts have been discontinued for some time, know anyone that sells/makes a suitable copy that fits correctly?

asphalt900 wrote:

I know those drive belts have been discontinued for some time, know anyone that sells/makes a suitable copy that fits correctly?


 

I have found a couple in really good shape on eBay, but they're not always available.

Oddly enough, the closest new item I've been able to find is a belt from an early 2000s Sportster. The KZ belt has a 14mm tooth pitch, 125 teeth, and is 1.25" wide; the Harley belt is the same except it's 1.125" wide (1-1/4" vs 1-1/8"). I don't know if the missing eighth of an inch is likely to cause any issues.

Note: there are also 129T belts for KZ440s but I'm not sure when/where they were used. I think it may be related to the two different rear pulleys that were/are available: one has four spokes and the other has five. According to Partzilla, the five-spoke pulley (part number 42041-5002) has 60 teeth but offhand I don't know how many the four-spoke one has. (Got 'em both in the basement - haven't counted the teeth yet ) 

OTOH also according to Partzilla both types were used on all 440 D models, so... I dunno

EDIT: on eBay right now there is a four-spoke pulley that is described as "65T", so maybe the four-spoke requires the 129T and the five-spoke requires the 125T - ??? (I don't believe there were multiple versions of the front pulley, so they all should be 24T)

Well I had no idea that a sportster belt might fit. I used to get replacements belts used on eBay. Last time I broke a belt I replaced it with my last spare and could not find any more used ones. So I ordered a chain and sprockets. When this last belt gives out I’ll switch to chain. 

I have gone through 4 or 5 belts in the last few years. Of course my belts were all used and on top of that were forty year old rubber. They just don’t have what it takes to last. Belts are nice until you have to replace them. Removing the swing arm is no fun  -especially if it hasn’t been removed in forty years. The first time I removed mine I had to destroy the swing arm axle just to get it off. 

Great Information to know Nerdy, think Bill Liked it too!! I don't know what my Friends 440 combination of pulleys has on it? Will have to wrestle with that task when it arrives.

Billeuze wrote:

Well I had no idea that a sportster belt might fit. I used to get replacements belts used on eBay. Last time I broke a belt I replaced it with my last spare and could not find any more used ones. So I ordered a chain and sprockets. When this last belt gives out I’ll switch to chain. 

I have gone through 4 or 5 belts in the last few years. Of course my belts were all used and on top of that were forty year old rubber. They just don’t have what it takes to last. Belts are nice until you have to replace them. Removing the swing arm is no fun  -especially if it hasn’t been removed in forty years. The first time I removed mine I had to destroy the swing arm axle just to get it off. 

I think condition and maintenance is everything, we managed three seasons of this kind of abuse without breaking a single belt (Buelle X1, HD-FXDX with screaming eagle stroker kit and a V-Rod)


 

Wow, Wookie,... are you THIS pictured stuntdriver, or member of this team???? Impressing!!!

Is this how you're going to treat your KZ when you get it finished Wookie haha.

MFP-Joe wrote:

Wow, Wookie,... are you THIS pictured stuntdriver, or member of this team???? Impressing!!!

I just turned the spanners Joe, Craig Jones was the rider(we also did a nitrous Buelle that he used to set a record of 148.7mph on a frozen lake in Sweden)