KZ440 cylinders on KZ400 engine

Thanks Nerdy, I actually figured that out 5 minutes after writing my question to Nessism

Wookie, thank you for your answer but I fail to see the point of adding a heat resistance sleeving if I have to use conventional heat shrink to seal it. It will be the same as what I have right now, no? My heat shrink protects the connectors and keep them tightly connected. If it leaks, then it will leak as well with heat resistance tubing sealed with heat shrink, no?
Is it to protect the wire itself?

Cheers,

Michel3007 wrote:

Thanks Nerdy, I actually figured that out 5 minutes after writing my question to Nessism

Wookie, thank you for your answer but I fail to see the point of adding a heat resistance sleeving if I have to use conventional heat shrink to seal it. It will be the same as what I have right now, no? My heat shrink protects the connectors and keep them tightly connected. If it leaks, then it will leak as well with heat resistance tubing sealed with heat shrink, no?
Is it to protect the wire itself?

Cheers,

The heat resistant sleeving (as used by the factory) helps prevent the wires and insulation from "hardening" due to heat and becoming brittle which make them susceptible to vibration fractures. The heat shrink is only to seal the ends

Got it, thank you Wookie !

Wookie, I know it's Christmas but I need some of your electric guidance
My repair didn't really work and I ordered and received a replacement alternator that turns out to have three wires instead of the two of my stock one.
If I am correct it means it is a three phase alternator instead of a single-phase, right ?
Can I still mount it though, by swapping the reg/rec with one from a KZ750 four cylinder ? Or is it not to be done ?
On the 750 reg/rec, there are a black/yellow, a brown, a white/red and three yellow wires. On the 440 one, there are a black/yellow, a brown, a white/red and two yellow wires. So, plug and play ?

Cheers

Not sure if this will be of any help or not, but if you have not read this post I might suggest you take a look at it.  There is discussion on 1,2 and 3 phase as well as mix and match of 12 and 18 pole items.  Further there is discussion on the different types of R/R to be used/

kzrider.com/forum/4-electrical/616145-1-...ase-upgrade-78-kz650

Thanks GD, I did find this topic yesterday and from what I read it looks like my kz440 rotor should work with the 3-phase stator but electricity is not my forte so I need a confirmation. I can test it but if it doesn’t work I won’t be able to return the stator anymore… 

Michel3007 wrote:

Wookie, I know it's Christmas but I need some of your electric guidance
My repair didn't really work and I ordered and received a replacement alternator that turns out to have three wires instead of the two of my stock one.
If I am correct it means it is a three phase alternator instead of a single-phase, right ?
Can I still mount it though, by swapping the reg/rec with one from a KZ750 four cylinder ? Or is it not to be done ?
On the 750 reg/rec, there are a black/yellow, a brown, a white/red and three yellow wires. On the 440 one, there are a black/yellow, a brown, a white/red and two yellow wires. So, plug and play ?

Cheers

In principle what you are suggesting would work as long as you use the corresponding regulator/rectifier "however" the rotor and stator are designed to work together and "mixing and matching" different parts may be less effective than original - I have put some of the potential issues below

• Is the rotor positioned correctly in the stator?
• Is the "air gap" between the rotor and stator correct?
• Is the mass of the rotor suitable for the three phase stator?

Any of the above being incorrect will have an impact on the generators output. Given that the stator cannot be returned once fitted (normal with electrical components) I would suggest sticking with the correct part for the bike (if necc you can have the original stator "re-wound")

Many thanks for your reply Wookie. Just had a technician from Wemoto, who sold me the stator, explain to me that apparently I can connect only two of the three wires and it will work. Sounds strange to me. What do you think ? After all they list this part as compatible for a kz440…

Michel3007 wrote:

Many thanks for your reply Wookie. Just had a technician from Wemoto, who sold me the stator, explain to me that apparently I can connect only two of the three wires and it will work. Sounds strange to me. What do you think ? After all they list this part as compatible for a kz440…

Well that would suggest that it will physically fit and function, if you decide to go this route then I personally would fit a three phase reg/rectifier and "use what I have" (all three phases) the stator appears to be common across the 400/440 range according to CMNSL so you have options
 

Michel3007 wrote:

Hi all,

Hope everyone is fine coming into the festive period.

Coming back to this topic to confirm that a kz440 cylinder block fits on a kz400h crankcase (which is the same as the 400B so should fit on these engines too) ! There is enough room for the cylinders. All I did was use a kz440 gasket set for the cylinder block, 440 pistons and rings. I also run 440 keihin cv36 carbs, with original airbox. The bike runs perfect. I will report once I have driven it for a longer period, didn’t have much time.

One question for you electricians out there, I had a problem with my stator wires (they were original and in a bad state so had to cut them off inside the case) which impacted my charging circuit. To repair, I used bullet connectors  inside the alternator case, covered with heat shrink tube. So far it seems to work but will it be ok in the long run ? Will the oil eventually lead to this repair to fail ?


Cheers,
 

Michael,

Great to hear the cylinders fit no problem to the 400 bottom end. Did you swap over the cam chain system (guides and chain) from the 440 to match or were you able to use the 440 tensioner on the 400 chain and guides?