KZ440 My first attempt

[PeanutHead]

Here is What I did last night. I started finishing the cluster temple with the actual parts I'd be using.

I spent a LOT of time measuring every half inch and marking the entire a grid.

I mocked up the start button, turn signal indicators, and oil light. I didn't mock up the ignition because I'm not sure how to mount it. I didn't like how the lights I wanted to use as indicators looks so I'm using the same style as the oil light.

And here it is, in its final resting place. I have to install the headlight to make sure there's enough room for the speedo.

[PeanutHead]

Mounted the headlight up and I kinda dig it and I kinda don't. I like it because I made the lights fit and work on the bike. I don't like them because they don't fill rhe fairing opening. I want to use this fairing because it looks cool to me and I already mounted a turn signal to it.

[PeanutHead]

So last night, I impressed myself. I wasn't sure if gutting the old sockets would work but it did! I cut the mounting points off the new lights and inserted them into the sockets for the original lights.

Here's the original speedo with the OE light.

And Now the new lights.

What a huge improvement.

[PeanutHead]

Not a whole lot to show tonight. Mounted the tail light and turn signals. I'm really liking the way they look together.

And I ordered a new 4x6 LED headlight. The set up I made just didn't seem to be as bright as I was hoping for.

I'll be grabbin a battery Sunday after work so I'll be playing with the wiring harness and electrical box next.

[PeanutHead]

So the 8 year old AGM battery I picked up from my brother STILL held a charge! Woohoo!!!!! The new LED light came in too so I spent all last night working on a mounting bracket (sorry no pics).

Today is ARTS & CRAFTS DAY!!!!!! While my boys (3 & 1) were having lunch, I colored the wires of my wiring diagram I printed (dunno why the color printer printed in Black&white). This copy was the cleanest I found, it should help me in the next few days after I finish with the headlight.

[PeanutHead]

The bracket system I came up with last night was going to be too tall to fit inside the fairing. So I scrapped it and finally came up with one that worked! I do have to make some minor adjustments to aim the light correctly but I'm very happy with it.

[PeanutHead]

So the wife and her best friend had a "Fancy tea party" for all our kids (total 5, ages 1-4). So i spent all day in the garage. Took me a while but its finally done! Well, the custom console/cluster that is.

[Hatchet54]

Cherry!

[dowood1]

Interesting build , looks like it’s being built to cover some serious miles

[Sky]

Suzuki gauge looks great in there!
The rest of your proportions are a little wonky.
That's a small bike.
All that fuel is unnecessary and quite frankly going to be top heavy (when full) for the little machine.
Not too late to source a smaller tank!
Maybe something off a dirt bike that will mimic the look of the fairing.

One of my early rides was a stripped down, hardtailed KZ400.
Front fender on the rear and a tiny peanut tank.
I could bench press that bike!
Rode her every day and still only had to visit the gas station once a week.

[PeanutHead]

Sky, I put the 5gal tank on the shelf for now. What's on her now is the stock tank. Now that you've put the idea of following the lines of the fairing, a Suzuki GS tank might flow better.

[PeanutHead]

I need to keep reminding myself to "K.I.S.S." (Keep it simple, stupid), well, for the most part. No pictures yet but last night I mounted the rear fender 100%. I used existing holes on the fender and had steel tabs I was gonna use as tank mounts that worked perfectly. Then I made an L bracket for the rear mount. After the boys go to bed, I'll snap some pictures.

I'm home alone with my 1 & 3 year olds because the wife had to go home for a family emergency (grandpa has cancer) so i might not have a lot of updates, AND I'll be back to work full time in 2 weeks too.

[PeanutHead]

Tonight was supposed to be the night I started wiring the 440 up but the kinda didn't happen. I installed everything back into the cluster, with their respected harnesses, pulled out the stock harness and the wiring diagram. And that's where my night ended. The colors don't match, so out came all the stock switches and such. And that's when i called it a night. I don't have the patience or time tonight to sort that all out.

Oh, and the battery is to big too.

[PeanutHead]

I had completely forgot that I had downloaded the repair manual and that had the correct diagram. I now have a slight problem. Since I want to clean up the the bars and have very little on them, what kinda problems will I have eliminating the distance sensor, self cancelling turn signal switch (replacing it with just a turn signal switch), and kill switch? Heres the harness.

[MrJ]

No issues chopping it out from what I remember. You can run the earlier style switch pod with a little rewiring too.

[PeanutHead]

Lunch time update. Last night I spent most of the time cleaning up my work table/toolbox top. After that, I modified the stock air box by cutting off the bottom half. Installed an aluminum plate on the bottom to seal it up. I don't wanna mess around with Pod filters and rejetting the carbs (unless it comes to that) since I have the "sought after snot box" that holds the stock air filter. I found the blank points cover I took off the blown motor that I wanna do something with. I used a little polish on it and decided a brushed look would be better. Today while my boys ate lunch (more like threw their food tobthe dogs) I used 320 grit to dull it up.

[PeanutHead]

Little but more progress today. My new battery came in so I started on the battery box modifications. If I just left it alone, I was worried that if I hit a bump hard enough I would damage the battery box. I cut about an inch out of the sides. Here it is mocked up.

Tomorrow i think I'm gonna remove a few tabs on the box and add the mounts for the new fuse box.

[PeanutHead]

Last night I welded the bottom of the battery box and test fit the battery. I knew it was gonna be too small, so luckily I had saved some toolbox foam. I cut it to fit around the whole battery but it was too much. So off came some. Then I placed it inside the frame. Tonight I'll be installing the mounts for the fuse box, CDI, flasher, and turn signal box.

[PeanutHead]

Wish me luck y'all. About to tear into this harness and slim it down. Hope I don't fuck anything up.

[PeanutHead]

I've been busy with work and life so Rusty got pushed to the back burner. A few days ago I fired her up and let her warm up for about 15 mins. She still backfired a bit so I decided to feel the exhaust to see if both cylinders were firing. Cyl 1 (left) was not! Ordered a New coil and waited for it to get here. Once it arrived I I installed it........same thing. She only ran on Cyl 2 (right). Switched plugs, no change but both plugs showed good spark. So I think I might need a new governor-breaker and or pulsing coil (showed some rust on it). Or so I thought.

Well, after looking up more parts, and sleeping on it, I switch out the spark plugs for shits and giggles. Just a stupid, bad spark plug was the problem!!!!!! So I took Rusty out for a shake down run and she got up to 50mph in 4th gear!! Damn this little thing is fun! I did, however, find out that the cylinder head is leaking but not surprising since it was sitting a while.