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KZ 440 Basketcase - AKA The "Pig" 18 Apr 2024 20:20 #897821

  • sf4t7
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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

1974 Z1A
1015
welded Z1 crank
Andrews 1X Cams
Delkevic 4 into 1

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KZ 440 Basketcase - AKA The "Pig" 19 Apr 2024 00:48 #897826

  • Wookie58
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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 !!)

 
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KZ 440 Basketcase - AKA The "Pig" 19 Apr 2024 05:27 #897841

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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.   
Scotty

1974 Z1A
1015
welded Z1 crank
Andrews 1X Cams
Delkevic 4 into 1
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KZ 440 Basketcase - AKA The "Pig" 20 Apr 2024 18:59 #897926

  • BruceinOH
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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. 
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KZ 440 Basketcase - AKA The "Pig" 20 Apr 2024 19:20 #897928

  • TexasKZ
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Excellent.
1982 KZ1000 LTD parts donor
1981 KZ1000 LTD awaiting resurrection
2000 ZRX1100 not ridden enough

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KZ 440 Basketcase - AKA The "Pig" 21 Apr 2024 05:32 #897936

  • Adrian719
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That is some excellent design on that filter box. Nice!

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KZ 440 Basketcase - AKA The "Pig" 27 Apr 2024 19:13 #898175

  • BruceinOH
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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….
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Last edit: by BruceinOH. Reason: Typo

KZ 440 Basketcase - AKA The "Pig" 28 Apr 2024 17:16 #898206

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

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