Slimming down wiring harness question.

So I'm in the process of finishing up my 82 KZ440 and have a few questions about the wiring harness. Will I have any problems if I eliminate the distance sensor in the speedo and self cancelling turn signal switch? What problems will I have if I eliminate the kill switch on the bars too?

I don't think you'll have any problems with the wiring, but I would keep the kill switch. Here's a KZR link that might be helpful:

Simplified wiring diagrams by loudhvx. KZR topic >> bare bones for mattylight >> Pg 1
a few of the diagrams may be missing. pages 11-on seem to have the most diagrams. Using an internet search, there's an 81 440 on pg 31. I did not look for any more.

Thanks a lot! I found one on a later page that has turn signals since I plan on running those.

Peanuthead wrote: Ok, here's the breakdown. Engine is a chain drive 82, it came out of an 82 frame (badges and vin said 82 A3 LTD), it's now sitting in an 81 frame.

I'm posting here so we don't fill up the mattylight thread with questions about a specific bike.

Have you taken the small ignition cover off? What was underneath? Points or electronic ignition?
It should have been electronic, but then do you have the igniter?

I agree, and thanks in advance for the help. I haven't taken the cover off yet but I did see the igniter box.

Ok, then assuming it has electronic ignition, the 1980 diagram won't be sufficient since it has points. I'll have to check a few diagrams to see if there are other significant differences, especially in the charging system.

So the diagram you want will include charging system, start system, ignition, headlight, tail light, brake light and turn signals.
No horn? I'll add it in case.

loudhvx wrote: Ok, then assuming it has electronic ignition, the 1980 diagram won't be sufficient since it has points. I'll have to check a few diagrams to see if there are other significant differences, especially in the charging system.

So the diagram you want will include charging system, start system, ignition, headlight, tail light, brake light and turn signals.
No horn? I'll add it in case.

You are awesome dude! Yes, all those please. Does there have to be anything special for the key to be the kill switch or just turning the key to off position work?

I know he's going to provide a complete diagram for you, but just an FYI: the KZ750M/K Twin models have the same ignition system as the KZ440s w electronic ignition >> same ignition coil, pulsing coil & igniter. but a different timing advancer as the timing curve is different. There's a 750-M1 wiring diagram on pg 17 of that bare bones topic. in case you want to get a head start on wiring the ignition system.

ps: you should clean, check & lubricate the timing advancer. get a new pulsing coil gasket beforehand. I keep several of those gaskets on hand.

You can leave the kill switch off. It's just a safety thing... in case you have to simultaneously use the front brake while trying to turn the engine off, like in case the throttle gets stuck open. Electrically, the ignition switch is enough to kill the bike, and the ignition switch is usually higher quality than the the kill switch.

If you want to leave off the kill switch, just replace the switch in the diagram with a wire. You still need the kill/start assembly for the starter button, unless you are asking if the ignition switch can be replaced with something like a car ignition switch.

As a side note, you might have a big turn signal switch assembly if you have the auto-cancelling turn signals. It's bulky, so if you want you can replace that with a smaller one from just about any Kz.

Yes I do have that big bulky switch. I'm replacing it with a universal turn switch. And no I'm not using a car ignition. Here's a picture of the cluster I made with all the headlight switch, power plug (for USB), start button, and ignition.

Cool. What's the toggle switch for?

That is the headlight switch. Its an On-Off-On switch.