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Author Topic: 82' KZ440 Cafe' Brat Build: Carb tuning & exhaust fly by!  (Read 99346 times)

Offline M.B Co

  • Posts: 614
Been lurking here for awhile. Now that I am getting some progress done I'll throw up some specs and pictures.

Started with:

1982' KZ440 LTD, 3rd owner (free from father-in law)
15K miles, all stock

I rode it stock for awhile until I had an idea of what I wanted to do. Then winter hit and the tear down started

What I started with:



Current setup as of September 2014

IMG_20140906_112140_1 by MBCo, on Flickr

IMG_20140906_112135 by MBCo, on Flickr

IMG_20140906_112158 by MBCo, on Flickr

IMG_20140908_192322 by MBCo, on Flickr

IMG_20140908_192834 by MBCo, on Flickr



Some minor mods like signals, LED tail, bars, removal of junk, trimmed seat,






Then the tear down (no need to post every picture of me removing items)





Engine Tear down started, cleaned, re-sealed. Ready for paint. Going with Gloss Black, polished bolt heads, polished side covers




Pretty nasty


Some new parts later, cleaned up

« Last Edit: Sep 30, 2014, 19:00:24 by M.B Co »

Offline M.B Co

  • Posts: 614
Re: 82' KZ440 Build
« Reply #1 on: Feb 27, 2012, 12:56:30 »
Moved on to the frame, started some small mock ups






Dropped the forks in the tree, may switch bars or move to clip on's. Not sure yet



Uni's. Going to try the can inside. If that fails, I got some jets to throw in and start that fun process



As she sits now

De-tabbed the frame. About 1lb of useless metal. Still need to grind smooth, finish & paint

Modified my signal stalks so they attach to my headlight bucket and hold it to the ears.

Painted 1 rear shock to see how it would turn out, good imo

Painted my fork lowers. Thought they turned out pretty good. Not show quality, but should hold up to the elements well.

Random mock up, still got some work ahead of me.















shiiiiny



Needs some touch up










Offline CafeRacer650

  • Posts: 353
  • Dream it. Build it. Live it.
Re: 82' KZ440 Build
« Reply #2 on: Feb 27, 2012, 16:58:53 »
From one fellow KZ lover to another... great work! Keep it up!!
Motorcycles are my personal art medium!
"Jellybean" Cafe Build - http://www.dotheton.com/forum/index.php?topic=41186.0

Offline M.B Co

  • Posts: 614
Re: 82' KZ440 Build
« Reply #3 on: Feb 27, 2012, 17:23:05 »
From one fellow KZ lover to another... great work! Keep it up!!

Thanks. My first motorcycle build, first Kawasaki, first KZ. Had a 04' GSXR 750 5 years ago and this little thing is a blast to ride.

Offline Shermanator86

  • Posts: 295
  • Big guy on a little bike
Re: 82' KZ440 Build
« Reply #4 on: Feb 27, 2012, 17:25:27 »
looking good man, think iv'e seen you on the twin owners forum as well
1978 kz 400 single carb, now 440 top end hybrid
http://www.dotheton.com/forum/index.php?topic=28708.0

2008 Suzuki SV650

Offline M.B Co

  • Posts: 614
Re: 82' KZ440 Build
« Reply #5 on: Feb 27, 2012, 17:37:53 »
looking good man, think iv'e seen you on the twin owners forum as well

Thanks! Yeah, I go there every so often. Need to update my thread over there as well.

I get my battery tomorrow. Then I'll start the electronic pan underneath the seat, can't wait.

Offline valvesprung

  • Posts: 1065
Re: 82' KZ440 Build
« Reply #6 on: Feb 28, 2012, 02:28:34 »
Diggin it! You'll definitely want different bars though. With stock foot controls super bike bars are a perfect fit on the KZ frames.
'79 KZ650SR (the show pony)
'97 Buell S3
1980 XS850

Offline M.B Co

  • Posts: 614
Re: 82' KZ440 Build
« Reply #7 on: Feb 28, 2012, 09:49:20 »
Diggin it! You'll definitely want different bars though. With stock foot controls super bike bars are a perfect fit on the KZ frames.

Thanks for the tip, I may change them out once I get it all back together.

Offline Big-D

  • Posts: 120
Re: 82' KZ440 Build
« Reply #8 on: Feb 28, 2012, 15:12:40 »
Coming along well, keep up the work

Offline M.B Co

  • Posts: 614
Re: 82' KZ440 Build
« Reply #9 on: Feb 29, 2012, 09:32:05 »
Thanks.

Going to get some work done tonight.

-Grind smooth the tabs I cut off
-Make my electrical pan
-Make the battery mount underneath the pan (battery will be mounted on it's side, terminals towards the front of the bike)