My build thread - KZ440
 

I picked her up yesterday. Can't wait to get off work today to get started. I am very new at this. So expect a lot of questions from me. 1979 KZ440. She runs but has some minor issues such a leaking carb boot and a seal behind the points.

My plan...Nothing elaborate. This is my first build. Hardtail, hand made seat, drag bars, exhaust wrap, maybe a peanut tank and forward controls. Rattle can paint job. Man am I excited

http://i199.photobucket.com/albums/a...0/100_3261.jpg

http://i199.photobucket.com/albums/a...0/100_3262.jpg

Oh wow....totally cool!

I've been really toying with the idea of buying an older bike like this, or a cafe racer type dealy, to ride on the street.

Can't wait to see the progress.

Let me know if you need any aftermarket custom help. I may have a guy for things...

Such as that seat you're talking about... I have a guy in michigan taht can do any leather, inlays, etc. Then a different guy in Jersey that will do custom tooled leather.

Trying to point tl at a cafe style bike ;) today I showed her a gpz550

Does she ride now?

Not sure I would've wanted it ages ago...but now that I'm more track than street I want something that I won't lose my license on for the street. Something that's a conversation piece and that'll make me smile when I ride it.

I think I might have the factory service manual on my home pc,

Thanks

Already downloaded, printed, bindered. Thanks anyway

Got the new battery charging. Picked up some new plugs at lunch. Tonight begins the process of getting her running. My wife is sooo gonna hate this thing :lol:

Ok cool. I had one a while back, tons of fun and easy to deal with when it breaks

I forgot to measure at lunch. What size pod filters do I need?

She knows how to, we had been slowly building her familiarity before I sold the 450. Trying to find an inexpensive replacement that she likes which will suit her better. So far she's pretty fond of savages :lol:

Bobber?

Definitely

Ok, had a pretty good night. Got the new battery on. Got new plugs in, and she started. Carbs need adjusting, no biggy. However, as the previous owner told me, I have a right side oil seal leak. Having some trouble getting the right side cover off due to one fucking nut....

http://i199.photobucket.com/albums/a.../rightside.jpg

The manual is pretty vague on how to hold this thing and get it off. Gonna sleep on it. It will probably jump out at me in the morning.

Any suggestions Derf?

All in all, it was a good day.

Brute force.

If I remember correctly you need to hold the crank from spinning on the other side (I think dont remember), and break it free. It should have been installed with locktight so it wont be easy to get off. Other than that nothing special to get it off

Make sure it's not "reverse thread"...:idk: barring that, I'd say impact wrench is the way to go.

THIS

Got the other side cover off. Went at it while sitting on the seat area and pulling like a mofo...nothing. Made a makeshift breaker bar out of two wrenches and voila, it broke.

Got inside it, and yep, oil seal busted. Also the pin that holds the timing mechanism to the crankshaft was sheared off. Went to the stealership and got the parts ordered.

While waiting on the parts, I started tinkering with the 1979 GS1000 that I picked up. But that will be another thread.

be careful breaking parts, kawi doesnt make parts for that bike anymore. You can find most parts on bike bandit or used, but I had a front frum on mine and there was a cable that was snapped when I bought it that doesnt exist, couldnt find one new or used, wound up having to have one made for $50

Here's an article regarding the same type of thing you want to do..

http://www.cyrilhuzeblog.com/2010/07...ne/#more-43848

Yep, the xs650 is very popular for this type of build. They are getting harder to find and the prices are going up. Here are some bad ass builds.

www.xs650chopper.com

There are a lot of build threads at these places. That is where I'm learning a lot

www.bobberforum.com

www.thechopperunderground.com

Damn that suck. I've got to go to Fatenal today to see about replacement engine cover screws. The dealership wants $2.78 per screw. Fuck that

Checked www.oldbikebarn.com yet?

Thanks Dave. Just got TWF back from being blocked at work.

I read this wrong. Def just went back in the thread thinking "wtf did I do now?" :lol:

:lol:

Still waiting on the damn oil seal. Gonna start cleaning out the tank tonight. May start fabbing the seat. Just ordered a leather stitching awl

Ok. A bit of an update. Still waiting on the oil seal. Here is why

http://i199.photobucket.com/albums/a...0/100_3305.jpg

Got the pin back in the crankshaft that seats in the backof the timing mechanism. It was sheared off. This is how it looked when I took the timing mech off

http://i199.photobucket.com/albums/a...0/100_3303.jpg

It took me the longest to drill out the old pin to make room for the new one.

I started on my seat. Not sure if I'm gonna stick with this one or start over.

http://i199.photobucket.com/albums/a...0/100_3308.jpg

Metal for the seat.

http://i199.photobucket.com/albums/a...0/100_3310.jpg

http://i199.photobucket.com/albums/a...0/100_3311.jpg

Camping foam
http://i199.photobucket.com/albums/a...0/100_3312.jpg

Here are tools I used to shape the seat
http://i199.photobucket.com/albums/a...0/100_3315.jpg

Waiting on the adhesive to set
http://i199.photobucket.com/albums/a...0/100_3313.jpg

Also worked on the cracked intake boots
http://i199.photobucket.com/albums/a...0/100_3298.jpg

http://i199.photobucket.com/albums/a...0/100_3297.jpg

More to come...as soon as the oil seal gets here.

Keep going

Just realized that I have no rectifier. I'll probably get a new one from Oregon Motorcycle Parts. They come highly recommended at the Kawasaki Twin Owners Forum. I'll let you know how it goes.

id say skip the filters and go with velocity stacks, and new rubbers(theyre cheap)

each time i built my kz, ebay and bikebandit were my friends

have fun!

whats u plannin on doin to the gs?

Good ideas. But right now I'm going real cheap. I might add those later.

As for the GS, not sure. I may just get it running and unload it. I figure I can get rid of it easier if it is running. Also, I've got a clean title. That should help.

Update.... Tonight we cooked out. After, dad and I started tinkering. We got the new oil seal in, tming mechanism on, points plate back on. Then new oil filter, filled it with oil. Reinstalled the carbs, put the tank on, hooked up the fuel line and vacuum line.

Turned on the switch, hit the button, and.....NOTHING. About that time, dad and mom had to go, my daughter wanted to play wii, so we stopped.

After some wii golf, bowling and boxing. Then some fairy tales and Spongebob book. I headed back out.

Ok, maybe we didn't line up the timing mechanism correctly? Nope, nothing. Maybe it has a clutch swich? I took the clutch cover off. Everything looked fine.

Just when I was about to go in for the night, I looked down. A lead from the starter relay was not connected. It matched the color of the wire beside it with the female connector. So WTF? it can't hurt. I plugged it in and......

SHE IS RUNNING!!!!!!!!!!!!!!!!!!!!!!!!!!!!!

So this means that the fun will now begin. Tomorrow, my wife, daughter and I leave for Gatlinburg for a few days. After that, Ms. KZ has an appointment with the sawzall.

Stay tuned........

Update...

What a night. Last night I began the teardown. Getting her naked and left with a pile of parts.

http://i199.photobucket.com/albums/a...0/100_3344.jpg

http://i199.photobucket.com/albums/a...0/100_3345.jpg

Dropped her to 7" and leveled her up with some lumber

http://i199.photobucket.com/albums/a...0/100_3349.jpg

Swingarm off. Ready to SAWWWWWWWW

http://i199.photobucket.com/albums/a...0/100_3350.jpg

The aftermath

http://i199.photobucket.com/albums/a...0/100_3351.jpg

Swingarm back on

http://i199.photobucket.com/albums/a...0/100_3352.jpg

Sat the tank back on to look at something that has been bothering me....

http://i199.photobucket.com/albums/a...0/100_3354.jpg

If I use the stock tank (which I plan on), there is not going to be enough room for my seat and the battery box and electrical box at stock length.

http://i199.photobucket.com/albums/a...0/100_3355.jpg

So I've decided to stretch it some. I've got my tubing coming on Monday. I plan on making my jig to keep the alignment. (I was planning on using the swingarm). But I really think I will like it better with a stretch. It will just take a little more work. Stay tuned

You going to hard tail it?

Yep. Tubing should be here Monday. Was planning on all straight tube, but now that I'm gonna add about 6", I'm thinking I will need to bend the bottom tube. Kinda dreading that, but I'll figure it out.

nothing to say, cept i like where this is going:rockwoot:

Ok, so I got a little more done last night in the heat.

First, made a jig to keep the alignment of my wheels.

http://i199.photobucket.com/albums/a...61747473_0.jpg

Measured for a possible 6" or 8" stretch

http://i199.photobucket.com/albums/a...61746710_0.jpg

Next, cut away the swingarm while keeping the axle plates

http://i199.photobucket.com/albums/a...61747143_0.jpg

Decided on the 8" stretch to give me plenty of room under the seat for the battery, electrical. Fixed a block in front of the rear wheel to keep it in place at my measurement.

http://i199.photobucket.com/albums/a...61746442_0.jpg

After blowing up my POS grinder and a trip to Lowes for a new one, lots of grinding

http://i199.photobucket.com/albums/a...61746111_0.jpg

My hardtail "kit" :lol:
http://i199.photobucket.com/albums/a...61745793_0.jpg

First piece cut and set in place for a look.

http://i199.photobucket.com/albums/a...61745334_0.jpg

http://i199.photobucket.com/albums/a...61744744_0.jpg

That was as far as I got last night. Tonight will be more cutting and fitting. Anybody got advice on notching the tubing to the axle plates? The way I'm doing it just doesn't seem right.

Try crushing it in a press.

Otherwise it all looks good. I am worried about the overall look with such a stretch. But I'm interested to see what u come up with.

Tubing notcher
 

The stretch looks really severe with it stripped down. By the time I put the seat, fender, and tank back on, it gives me just enough room to be comfortable. Also, once I get the hardtail on, I will run the forks back down in the triples. Right now it looks like the front end is mashed in.


That looks cool. Thanks for the link

Question; wouldn't it make your life a lot easier if you took the engine out of the frame? Plus it would give you an opportunity to clean it up and possibly brighten it with polish or paint. Just asking.

Yes, yes it would

Oh okay... I hope you don't think I was being offensive. I actually thought you had some really good reason for leaving it in so I hesitated to ask and look stupid...:lol:

:lol: No offense taken. I just haven't done it. So when you asked that, I had nothing to say other than just agree. I'm gonna get it put together and rideable for now. Winter will bring the complete tear down, paint, etc. It will be rat-tastic til then.

Wooohooo. She is out of the jig. Next, I gotta make the templates for the gussetts. Then off to the welder. I've got everything tacked into place with my borrowed flux core setup. And no, there will be no close ups of my welding :)

http://i199.photobucket.com/albums/a...0/100_3371.jpg

http://i199.photobucket.com/albums/a...0/100_3369.jpg

http://i199.photobucket.com/albums/a...0/100_3370.jpg

This kinda reminds me of building a house. When you build a house, once the walls are up, you think you are almost done. Wrong! Just like with this...there are dozens of tasks left to do. Been a great learning experience so far.

Nice stance. Looking sweet!

Thanks dude

I like it... even though I'm still unsure about the added length. But I know you have a vision so I won't doubt it... keep up the good work.

Thanks. Once the seat goes on, you will see it. The bike looks much bigger in pics than it really is. Remember, it is a 1980 440cc. That thing is small.

Just dropped it off at the welder's place. He and I are gonna work on it tomorrow afternoon.

Awesome. Try to get some action picss of the welding!

I keep forgetting that it's a 440 as well... I keep worrying about stability and swing arm strength, etc but then I remind myself and realize that it'll be fine.

Ok...bike is at the welder's. He and I are gonna work on it Tues night. In the meantime, I decided to finish my seat.

Got the fabric glued in place
http://i199.photobucket.com/albums/a...84909088_0.jpg

Stitched
http://i199.photobucket.com/albums/a...84909756_0.jpg

Trimmed
http://i199.photobucket.com/albums/a...84910368_0.jpg

The color scheme is gonna be black with red wheeels. That's why I'm going with the red seat.

FYI...My fingers hate me for the hand stitching LOL

Pimp!

Looks Sweet. Wish I could have done that with the project bikes I have received and been rid of. ehh, Gas?

Thanks. My friend and I will be welding her up tomorrow night (hopefully)

I'll give you "project bikes"... mofo.... you don't have projects... you have crap heeps that you leave stranded on my lift for weeks or months on end. Then do nothing with!

You want to do something... I'll get my sawzall and we'll have at that rebel in your shed that you have done NOTHING to all year.

Mofo talkin to me about projects... why I awt to.... remember mofo where you bike sits this very second. Grrrrrr


:D

:lol: Sounds like my brother. That is how I ended up with 2 project bikes. I told him what I was doing, and he said,"find me one." So I find two as a package deal. Then his wife vetoed that shit. She was like "You've got three fuckin boats and Jeep that you've been going to "restore" for two fuckin years. Nope, the bike ain't happenin."

So now I've got a 1979 GS1000 that I need to sell :lol:

Oh and BTW...if you do tackle the Rebel and hardtail it, keep the shocks. There is a market for them for guys that wanna lower the rear of some older bikes and keep it soft

Good to know...

Your bud and his wife sound like cave and his wife. This idiot cave keeps talking about wanting a sportbike. It took him nearly 3 years and almost a divorce to get his current bike. Plus he's got a gajillion points on his record, he needs a sportbike like I need another hole to shit out of.

:lol

Hey now, I didn't have to fight for 3 yrs for this bike. Just had to fight for 3 wks to step up the schedule from fall to spring purchase. However, the sportbike idea is kinda far-fetched. I am 33 with two kids and a job that requires my being able to walk. So if I wipe it doin what I want the bike for then there will either be only a grease stain left or several non-functioning limbs. and I know where my bike currently sits, if anything happens to it while it sits there.........well, lets just say there will be more than just hell from me to pay. Wife will be highly pissed off as well, and you know what they say about women......Hell hath no fury

Last night: Finished making my seat bungs, got the springs on my seat, and mocked up. Also had to put the buckhorn bars back on. The brake reservoir wouldn't fit on the drag bars, not enough room.

http://i199.photobucket.com/albums/a...0/100_3393.jpg

Got lots of grinding to do, but here is my seat setup so far
http://i199.photobucket.com/albums/a...0/100_3397.jpg

Shot of the gussetting
http://i199.photobucket.com/albums/a...0/100_3398.jpg

http://i199.photobucket.com/albums/a...0/100_3394.jpg

http://i199.photobucket.com/albums/a...0/100_3395.jpg

Dont wear a long shirt, hehe

:lol: Good advice

Keep up the good work. I'm dying to see how it will turn out.

You need forward controls and a lower/wider gas tank. It's looking good so far though.

Both good recommendations, but just not in the budget right now. Thanks

A couple of pics in the sun. Exhaust is back on. Electrical box installed. Still have some wiring to clean up. Battery box in place. Just ordered my new chain today. Scored a skatebaord wheel from the local shop to turn into my chain roller.

http://i199.photobucket.com/albums/a...18749488_0.jpg

http://i199.photobucket.com/albums/a...18750290_0.jpg[hr]
Checklist of things left to do...

Chain roller
Hook up all electrical
Build tail light/tag bracket
Wire up tail light
Get chain on
Strip/clean tank. Bondo where the badges were.
Paint tank
Carbs and filters back on
Mount a pivot for rear brake lever
Clutch needs adjusting
Paint handlebars
Install grips
Order tires
Paint wheels/mount tires

It seems like there are a million small tasks on this project. I'm really enjoying it, though.

what kinda tail light/ plate combo u thinkin of using? i might have something in the garage for ya

when i was on a budget, i rocked cheng shin tires on the kawi for awhile, 19" front, 16" rear

I'm gonna fab a side-mount plate/light bracket. I just bought a simple, round trailer tail light for it. Decided not to run turn signals yet. Just going simple

I'll have to check those tires out. I have found a place that I can get a set of dunlops for $130 a set

Just found em. I'll be ordering the cheng shin tires today. Thanks D

no prob- im taking the side mount and light off my kawi, yours if you want it. also got a drag specialties taillight i never used

Thanks for the offer, but I've got all the parts I need to fab one up.

That is a sweet Kaw you got.

thanks, its not as convienent or smooth as a busa, but its got soul, and its superbad lol

no problem on the parts, just offering. i gotta lil soft spot for the old kaws, i like how yours is looking too

Hahaaa. Had some wiring issues. So I decided to start from scratch and get rid of a bunch of useless crap. Here is what I accomplished during lunch. :lol: The good news is that I took out a dozen or so wires and a couple of switches, and I still have a good circuit.

http://i199.photobucket.com/albums/a...25747084_0.jpg

Going from this....
http://i199.photobucket.com/albums/a...l_Page_247.jpg

To this...
http://i199.photobucket.com/albums/a...Simplified.jpg

That looks like a nightmare. Good luck.

Can't see those wiring diagrams real good on the phone but anytime u eliminate unneeded wiring, you're better off. Less likely to have a short or bad grounding that f's up all kinds.

Spent this weekend getting the electrical system back together. Pretty proud of myself. Put my ignition in my electrical box, and it turned out great. Got the carbs and tank back on, and she fired right up. But I've got some adjusting to do.

Things left to do
1. Fab work to reinstall the rear brake pedal
2. Adjust clutch (not engaging)
3. Install chain roller and chain
4. Carb adjustment
5. New tire

Then it is time to ride. Various cosmetic work during the winter

Uploading pics now[hr]
Making my tag bracket.
http://i199.photobucket.com/albums/a...32747438_0.jpg

http://i199.photobucket.com/albums/a...32747954_0.jpg

http://i199.photobucket.com/albums/a...32748363_0.jpg

Installed
http://i199.photobucket.com/albums/a...32749002_0.jpg

Got her back together

http://i199.photobucket.com/albums/a...32744985_0.jpg

http://i199.photobucket.com/albums/a...32746529_0.jpg

nice

Tires came in today. Thanks for the heads up Dnyce. Got the Cheng Shins for $85 delivered.

no prob, i put a few thousand miles on some cheng shins, and alot of blistering 12 second 1/4 mile passes too lol

Lookin good.

What do you plan on doing with the rims? Leaving or powder or what?

They're gonna be red. Paint for now. Powder in the future. Everything will be black. Red wheels, seat, and grips

Let's play "What's wrong with this picture?
http://i199.photobucket.com/albums/a...-41-26_950.jpg

You forgot to put the cap back on the green pen. :wink:



















Also, you may want to locate the other half of that float. :lol:

Not just the other half, but it's also bent all to hell. Retail on the float is $43.05. Just ordered one shipped for $19 on fleabay

damn, beat me to it :lol:

This spring weather has given me the build fever. So last night I made a little progress.

First, I have a bad front brake light switch. Ordered one through the dealership. Got a call yesterday that the switch is discontinued. Then I found one of my new favorite parts site, www.z1enterprises.com . I didn't see what I was looking for online. So I called them. The guy was really helpful and steered me to what I need. It is a banjo bolt/switch. Cool, huh.

So I went home and took out the banjo bolt to make sure I had the correct pitch to order the new one. That led me taking a look at the master cylinder. Holy crap that thing was nasty. 30 yr old brake fluid and gunk. Took it apart and cleaned it good. Put it back on and flushed all the old dark brown fluid. Got some fresh fluid in and bled the line. Got good pressure. So I have brakes.

Still waiting on the switch and the carb float.

Gonna get with my welder friend to help me with remounting the rear brake pedal, fender tabs, and chain roller.

I can actually see the end in sight. Gonna be riding her this spring.

Ok, got the banjo bolt/brake light switch on. Works great. Got the rear brake brace welded up. Welded the chain roller tab on. Gotta figure out my clutch issue, slap a chain on, and its all cosmetic after that. Here is the roller.
http://i199.photobucket.com/albums/a...-28-24_615.jpg

http://i199.photobucket.com/albums/a...-28-33_746.jpg

sweet

Worked on the tank today.
Here's what I used to fill where the emblem was. This stuff was great.

http://i199.photobucket.com/albums/a...-54-27_193.jpg

Primed

http://i199.photobucket.com/albums/a...-30-38_124.jpg


Sat it on her briefly. Gotta clear coat it next.

http://i199.photobucket.com/albums/a...-43-29_830.jpg

You could have gotten TL to do the tank for you, she just finished doing daves tank and I'm sure she has some free time

FIRST RIDE TONIGHT!!!!!!!

Just over 10 months and a rough winter, she hit the road tonight. Still gotta finish my fenders, but I'll be ridin her to work tomorrow. I'll get better pics in the morning

http://i199.photobucket.com/albums/a...-51-11_480.jpg

So...how's it ride? Looks sweet.

Rough :lol:

Nah, not so bad. Runs great and straight. Cool to putt around town. I won't be taking it cross country

Yeah, I kinda gathered it wouldn't be the right mount for 300 mile jaunts, but for cruising, it looks quite tits.

Can't wait to see it with the fenders on...

Daylight shot

http://i199.photobucket.com/albums/a...-25-55_882.jpg

P.H.A.T. Great job!!!

Thanks dude

I love the punky brewster belt holding the battery! Seriously it's a cool ride you have there, looking forward to my next future build.

:lol: Raided the wife's belt stash last night. Thanks

sweet looking,
hows it sound?