DO THE TON

Blood Sweat Tears and Grease => Projects => Cafe Racers => Topic started by: noahdog on Nov 06, 2009, 20:07:44

Title: 1977 KZ400 Build "Logan's Run"
Post by: noahdog on Nov 06, 2009, 20:07:44
Ok here's my first real attempt at a cafe racer.  After I picked up the KZ400 and saw the straight lines of the frame I knew it was begging to be cafe'd out. The original tank was beat to hell. It only has 2K miles but it'd had a very rough life in the garage it seems. So I picked up a better tank and left side cover off Ebay and some clubman bars from a local shop and the project begins.

(http://i486.photobucket.com/albums/rr226/noahnsteph/KZ400%20Cafe%20Project/P3310150.jpg)
(http://i486.photobucket.com/albums/rr226/noahnsteph/KZ400%20Cafe%20Project/P3310151.jpg)
(http://i486.photobucket.com/albums/rr226/noahnsteph/KZ400%20Cafe%20Project/PA060202.jpg)
(http://i486.photobucket.com/albums/rr226/noahnsteph/KZ400%20Cafe%20Project/PB050086-1.jpg)

Next I started on a seat and some rear sets. The seat is still in the beginning stages, being made from the rear of the old beat up tank. I'm still up in the air at this point especially since one of our fine members has a seat that would fit just about perfectly on my frame.  http://www.roccitycafe.com/item.php?path=store/cbss,

(http://i486.photobucket.com/albums/rr226/noahnsteph/KZ400%20Cafe%20Project/PA100215.jpg)
(http://i486.photobucket.com/albums/rr226/noahnsteph/KZ400%20Cafe%20Project/PA100215.jpg)
(http://i486.photobucket.com/albums/rr226/noahnsteph/KZ400%20Cafe%20Project/PA090211.jpg)

While I decide on a seat I went to work on mocking up some rearsets.  I picked up a pair of YAMAHA YZF-R1 rearsets from 2 different auctions for less than $50 and mounted the pegs and levers to the stock passenger peg mounts.  I still need to remove the stock controls and re-bend the brake linkage since I made the second bend too close to the first but I have a functional mock up on both sides.

(http://i486.photobucket.com/albums/rr226/noahnsteph/KZ400%20Cafe%20Project/PB050079.jpg)
(http://i486.photobucket.com/albums/rr226/noahnsteph/KZ400%20Cafe%20Project/PB050080.jpg)
(http://i486.photobucket.com/albums/rr226/noahnsteph/KZ400%20Cafe%20Project/PB050081.jpg)
(http://i486.photobucket.com/albums/rr226/noahnsteph/KZ400%20Cafe%20Project/PB050082.jpg)

I'm also thinking about a small fairing for the front. I'm torn between a more traditional cafe 1/4 fairing like this... http://cgi.ebay.com/ebaymotors/Viper-Sport-Cafe-Fairing-for-Motorcycles_W0QQcmdZViewItemQQhashZitem518d9445f7QQitemZ350267655671QQptZMotorcyclesQ5fPartsQ5fAccessories

 or a more modern dual headlight fairing like this... http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&item=130339716949&viewitem=&sspagename=STRK%3AMEWAX%3AIT

I look forward to comments and tips.






Title: Re: 1977 KZ400 Build
Post by: Hannibal Smith on Nov 06, 2009, 20:34:35
Starting to shape up!

My secret favorite old school bikes are the KZ series, as they are true "Mad Max" machines. My next Japanese bike will probably be a KZ 1000.
Title: Re: 1977 KZ400 Build
Post by: boomshakalaka on Nov 07, 2009, 06:28:26
definitely go with the classic bullet fairing unless the rest of your bike is going to be pretty far outside the box.  I think the modern dual headlight fairing will look out of place on an otherwise period appropriate cafe bike.
Title: Re: 1977 KZ400 Build
Post by: crazypj on Nov 07, 2009, 07:17:04
I think your going to find your rearsets are a bit 'land speed record' position (bit low and too far back)
They will probably point your toes straight down and severly reduce cornering clearance.
 When you move your foot it will place more weight on wrists and upset handling in corners
Get seat finished, fit bars your going to use and find out the 'correct' position then weld (or have someone) weld in new mounts.

PJ
Title: Re: 1977 KZ400 Build
Post by: hillsy on Nov 07, 2009, 11:08:53
It only has 2K miles but it'd had a very rough life in the garage it seems.


That might be 102K miles.

I agree that the rearsets are probably too far back, you could probably just weld a bit of plate in the triangle area (just ahead of the passenger peg mounts) and mount them there. Or cut those triangles off and weld some tabs to the main frame.
Title: Re: 1977 KZ400 Build
Post by: noahdog on Nov 07, 2009, 12:28:56
That might be 102K miles.

I agree that the rearsets are probably too far back, you could probably just weld a bit of plate in the triangle area (just ahead of the passenger peg mounts) and mount them there. Or cut those triangles off and weld some tabs to the main frame.

Judging by the compression and how well it runs I'm betting that it's actually is just over 2K miles.

I'm giving some serious thought to just cutting the triangle frame for the passenger pegs off all together and welding some mounting tabs for the original brackets for the rearsets I bought.

Here's pics of the rearsets complete with the original brackets.

(http://i486.photobucket.com/albums/rr226/noahnsteph/KZ400%20Cafe%20Project/LeftRearset.jpg)
(http://i486.photobucket.com/albums/rr226/noahnsteph/KZ400%20Cafe%20Project/RightRearset.jpg)

If I move them forward and up as is being suggested should I try to just run a linkage from the new brake pedal forward to the stock brake lever assembly? With the original pedal cut off of course. ;) Or do I continue with the plan of making a new linkage back to the drum?
Title: Re: 1977 KZ400 Build
Post by: boingk on Nov 07, 2009, 20:16:09
Good score if it really is 2k on the odometer, thats a champion find. Give it some love and you'll really appreciate the ride this one'll give you.

On the rearsets, I'd make a new linkage straighjt to the rear drum. The less linkages the better for anything like that. Are you planning on removing the standard pegs and controls?

 - boingk
Title: Re: 1977 KZ400 Build
Post by: crazypj on Nov 07, 2009, 21:16:59
If you move them forward you won't need to have them sticking out so far (silencer is smaller diameter closer to front)
 I would 'beat' silencer/pipe for clearance on brake pedal.
 I don't think I've ever seen anytrhing that resmbles a good looking brake rod set up unless it was direct from factory,( and some of them pretty dismal) Running to cut down brake pedal will probably be easiest/safest thing and doesnt look 'too' bad
 Any rod with bends in looks awful in my opinion.
 I have a plan for my 360's which should look less shite and also not operate brake with suspension movement.

PJ
Title: Re: 1977 KZ400 Build
Post by: noahdog on Nov 08, 2009, 12:01:46
Good score if it really is 2k on the odometer, thats a champion find. Give it some love and you'll really appreciate the ride this one'll give you.

On the rearsets, I'd make a new linkage straighjt to the rear drum. The less linkages the better for anything like that. Are you planning on removing the standard pegs and controls?

 - boingk

Yeah the stock pegs and controls are coming off.  I just haven't gotten around to it yet.
Title: Re: 1977 KZ400 Build
Post by: noahdog on Nov 08, 2009, 12:14:52
If you move them forward you won't need to have them sticking out so far (silencer is smaller diameter closer to front)
 I would 'beat' silencer/pipe for clearance on brake pedal.
 I don't think I've ever seen anytrhing that resmbles a good looking brake rod set up unless it was direct from factory,( and some of them pretty dismal) Running to cut down brake pedal will probably be easiest/safest thing and doesnt look 'too' bad
 Any rod with bends in looks awful in my opinion.
 I have a plan for my 360's which should look less shite and also not operate brake with suspension movement.

PJ

Unfortunately after looking at the bike last night I realized that the stock brake assembly is attached to the frame for the passenger pegs that I plan on cutting off in order to mount the rearsets. Looks like I'll be running a rod back to the drum instead
Title: Re: 1977 KZ400 Build
Post by: Big-D on Nov 13, 2009, 11:57:15
Bike is coming along well, should be fun when its done.
Title: Re: 1977 KZ400 Build
Post by: noahdog on Nov 13, 2009, 16:49:31
Well I sold the set of rearsets I was trying unsuccessfully to use to a fellow member here and ordered up a set of universal ones from Thailand so when they show up in probably 3 weeks  >:(  I'll get them mounted.  I'm hoping to get the cut up tank welded onto the seat base I made this weekend so I can start bondoing the dents and getting it ready for paint.
Title: Re: 1977 KZ400 Build
Post by: noahdog on Nov 29, 2009, 12:35:51
The rearsets finally arrived from Thailand so I started cutting and grinding to to make room for them and of course drop a few pounds. ;)

(http://i486.photobucket.com/albums/rr226/noahnsteph/KZ400%20Cafe%20Project/PB280095.jpg)
(http://i486.photobucket.com/albums/rr226/noahnsteph/KZ400%20Cafe%20Project/PB280096.jpg)
(http://i486.photobucket.com/albums/rr226/noahnsteph/KZ400%20Cafe%20Project/PB280098.jpg)

I think I can get the rod going back to the rear drum to clear the swing arm  if I flip the lever on the drum to point up instead of down. Won't know for sure till I get the rearsets mounted and bend the rod but trying to run the rod under the swing arm doesn't look possible

I've also got a sweet  1/4 fairing on it's way thanks to another fine member here on the forum.  It's scheduled to get here wednesday which just happens to be our weekly bike night. ;D Hopefully I can get that mounted and get pics then I'll go back to work on the rearsets. Just need to weld on some mounting tabs and get the linkages sorted out.



Title: Re: 1977 KZ400 Build
Post by: noahdog on Dec 03, 2009, 17:52:22
Hmm, it seems the clubman bars aren't going to work with the new fairing. It hits the master cylinder on the brake handle long before it's lined up with the bucket so it looks like I'll be picking up a pair of drag bars. Anyone interested in a set of very slightly used clubmans? ;)
Title: Re: 1977 KZ400 Build
Post by: troybilt on Dec 03, 2009, 18:43:22
Looking Good Noah. I agree with Pj on that you might want to get the seat (and tank) taken care of before positioning the rearsets. They will dictate where the rear sets need to go for sure.
And I'd like to say that thing is amazing clean too. My guess would be 2k might be right.
Title: Re: 1977 KZ400 Build
Post by: noahdog on Dec 03, 2009, 22:12:47
Looking Good Noah. I agree with Pj on that you might want to get the seat (and tank) taken care of before positioning the rearsets. They will dictate where the rear sets need to go for sure.
And I'd like to say that thing is amazing clean too. My guess would be 2k might be right.

Good point, I'll probably wait on positioning the reasets till after I get the new bars and the seat done so I know how high I'll be sitting. I suddenly went from twiddling my thumbs  waiting on parts to work on to so many things to work on it's dizzying. ;D
Title: Re: 1977 KZ400 Build
Post by: noahdog on Dec 10, 2009, 13:36:55
Got the new dragbars installed last night. They will work perfectly and still give me a similair stance as the clubman bars did which is good. The fairing will now fit once I trim it a bit to fit around the tach and speedo. Here's the fairing I picked up from another member here on DTT.
(http://i486.photobucket.com/albums/rr226/noahnsteph/BubbleFairing.jpg)

Once I get it trimmed I need to make some mounting brackets and figure out what to do about turn signals. I'm torn between having them stick out from the side and mounting some flush mount signals onto the fairing itself.

I'm pretty sure I'll have to get some bar end mirrors which is fine since that was the plan anyway. I don't think any stock mount mirrors would clear the fairing. I really wish there were such a thing as bar end mirrors with built in turn signals but so far I can't find any.

Any suggestions on the front signals would be appreciated. I've got a set of small bullet signals for the rear but they clearly won't work for the front.
Title: Re: 1977 KZ400 Build
Post by: VonYinzer on Dec 10, 2009, 13:52:54
Once the fairing is mounted up, find an appropriate place and drill some holes to mount the signals right in the fairing. Fiberglass can always be fixed if ya change your mind down the road...
Oh ya, still have those clubmans? If so, how much shipped to 15009?
 Thanks man, Mike.
Title: Re: 1977 KZ400 Build
Post by: noahdog on Dec 10, 2009, 13:57:09
I'm afraid I sold the clubmans to troybilt who ironically had the fairing originally but sold it to kanticoy who wound up not using it and selling it to me.  ;D

I'm thinking of using a pair of flush mount signals mounted through the existing holes to also hold the mounting bracket on. The trick is finding the right size and mounting style.
Title: Re: 1977 KZ400 Build
Post by: Maritime on Dec 10, 2009, 16:27:26
Got the new dragbars installed last night. They will work perfectly and still give me a similair stance as the clubman bars did which is good. The fairing will now fit once I trim it a bit to fit around the tach and speedo. Here's the fairing I picked up from another member here on DTT.
(http://i486.photobucket.com/albums/rr226/noahnsteph/BubbleFairing.jpg)

Once I get it trimmed I need to make some mounting brackets and figure out what to do about turn signals. I'm torn between having them stick out from the side and mounting some flush mount signals onto the fairing itself.

I'm pretty sure I'll have to get some bar end mirrors which is fine since that was the plan anyway. I don't think any stock mount mirrors would clear the fairing. I really wish there were such a thing as bar end mirrors with built in turn signals but so far I can't find any.

Any suggestions on the front signals would be appreciated. I've got a set of small bullet signals for the rear but they clearly won't work for the front.

That makes a lot of sense, bar end mirrors with signals......I bet yo could get some Led's that could mount pretty small on the backs of some mirrors and look good. .... I like that idea, a good looking set would probaly sell on ebay too.
Title: Re: 1977 KZ400 Build
Post by: noahdog on Dec 10, 2009, 16:33:43
Yeah especially since I replaced the clubmans with dragbars which would be infinitely easier to route the wires through.
Title: Re: 1977 KZ400 Build
Post by: diesel450 on Dec 11, 2009, 23:47:57
Hey!!! Thats my coffee table!? and that used to be my fairing! I love it, how stuff gets passed around. Looking forward to seeing how this comes together.

As far as your seat goes; you can't get more symetrical lines that the rear end of the same tank. I like the look of that!

BTW; that fairing came to me with a 1968 Benelli 125 cobra I bought this summer. It was WAAAYYYY too big for it though.
Title: Re: 1977 KZ400 Build
Post by: troybilt on Dec 12, 2009, 00:53:07

seven degrees of seperation right?  That is too funny, I couldn't even remember where I bought it from. I think it's a sign that I've bought and traded too much stuff.
Anyhow Noah, I have some very small clear signals (brand new) that should mount right in those holes. I'm not using them. I'll be pretty busy over the weekend but I'll try to get a picture at some point.
Title: Re: 1977 KZ400 Build
Post by: noahdog on Dec 12, 2009, 02:30:43
Oh how the karma and parts flow through this forum. ;D  Hell yeah Troy I'd love to see a pic of the signals.

I can definitely see how this faring was huge on a 125 but it looks like it will fit perfectly on my 400.
Title: Re: 1977 KZ400 Build
Post by: noahdog on Dec 14, 2009, 16:02:55
Here's a link to the flush mount turn signals that I'm considering using on my fairing.   http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&item=280413898653&viewitem=&sspagename=STRK%3AMEWAX%3AIT

They would double as turn signals and the mounting bolt so speak to bolt the mounting bracket to the fairing.  If I used regular small bullet style lights they'd be pointing cross-eyed but the flush mount ones light up fully and are more non-directional.

My only concern is that they may look too modern for a vintage fairing and cafe bike.

What do you folks think?
Title: Re: 1977 KZ400 Build
Post by: ridesolo on Dec 14, 2009, 16:19:42
What do you folks think?

The folks here use other 'modern' things like Carbon Fiber, CNC machined aluminum bits, modern front forks, and the like, I can't really see that there's much that wouldn't work, especially if it's what YOU like on YOUR bike.  Of course, I'm not a stickler for things being 'pure and authentic.' ;)
Title: Re: 1977 KZ400 Build
Post by: diesel450 on Dec 15, 2009, 01:15:15
The folks here use other 'modern' things like Carbon Fiber, CNC machined aluminum bits, modern front forks, and the like, I can't really see that there's much that wouldn't work, especially if it's what YOU like on YOUR bike.  Of course, I'm not a stickler for things being 'pure and authentic.' ;)

+1 on this. It depends on what you are looking for. If you want a real vintage feel then these will probably not work. If you only want to hint at that and do your own thing then sky's the limit.
Title: Re: 1977 KZ400 Build
Post by: noahdog on Dec 15, 2009, 12:02:15
Ok how's this for an idea. The clear flush mount turn signals might not stick out like a sore thumb if I make it a theme. How about using a clear brake light and signals to tie it all together. Here's all 3 to show you the combo I'm thinking of using..

These mounted to the front fairing
(http://i486.photobucket.com/albums/rr226/noahnsteph/KZ400%20Cafe%20Project/signal4.jpg)

And these at the rear
(http://i486.photobucket.com/albums/rr226/noahnsteph/KZ400%20Cafe%20Project/TurnSignals.jpg)

With this tail light tucked under the gas tank rear end seat bump.
(http://i486.photobucket.com/albums/rr226/noahnsteph/KZ400%20Cafe%20Project/TailLight.jpg)
Title: Re: 1977 KZ400 Build
Post by: diesel450 on Dec 15, 2009, 12:06:34
I think that could work and would definitely improve safety. I need to see the bike done and the lights mocked up though. Get to work! ;D
Title: Re: 1977 KZ400 Build
Post by: noahdog on Dec 17, 2009, 00:23:38
Looks like the new bars will work nicely. I trimmed the fairing to fit around the gauges tonight and did a quick mock up.
 
(http://i486.photobucket.com/albums/rr226/noahnsteph/KZ400%20Cafe%20Project/PC160004-Copy.jpg)

(http://i486.photobucket.com/albums/rr226/noahnsteph/KZ400%20Cafe%20Project/PC160005.jpg)

Before I could even get the fairing mocked up I had to drop the front end and take the top of the triple tree apart to swap the fork ears with a pair I picked off Ebay since the original ones were pretty bent up and out of shape from a previous drop I'd guess.




Title: Re: 1977 KZ400 Build
Post by: Kanticoy on Dec 17, 2009, 00:59:09
good job man!

I think that this fairing has finally found its home!  And I like the clear lens idea BTW.
Title: Re: 1977 KZ400 Build
Post by: diesel450 on Dec 17, 2009, 01:28:01
Fairing Looks great! Looks like a lot of windscreen though, could just be those pics though. I like the strategic use of PBR's  ;D
Title: Re: 1977 KZ400 Build
Post by: beater on Dec 17, 2009, 01:43:24
ahhh, a welder, a motorcycle and pbr's


Title: Re: 1977 KZ400 Build
Post by: diesel450 on Dec 17, 2009, 01:54:31
Been keeping emergency rooms busy since 1900 at least!!
Title: Re: 1977 KZ400 Build
Post by: noahdog on Dec 17, 2009, 09:17:56
Been keeping emergency rooms busy since 1900 at least!!

PBR me ASAP!  Thanks, now call 911 ;D
Title: Re: 1977 KZ400 Build
Post by: noahdog on Dec 17, 2009, 10:26:32
good job man!

I think that this fairing has finally found its home!  And I like the clear lens idea BTW.

I think I may have finally found a name for the bike. My buddy Dave, who's garage we all work on our bikes in, thinks that the clear lights with the retro fairing on bike will give it a 70's futuristic look ala Logan's Run.  ;D
Title: Re: 1977 KZ400 Build
Post by: diesel450 on Dec 17, 2009, 11:58:03
I love it! That could help you with a color scheme too, if you haven't already settled on one. I seem to recall a lot of matte silvers and grays on that film but I could be dead wrong.
Title: Re: 1977 KZ400 Build
Post by: noahdog on Dec 17, 2009, 12:10:08
I love it! That could help you with a color scheme too, if you haven't already settled on one. I seem to recall a lot of matte silvers and grays on that film but I could be dead wrong.

True, the vehicles are all silver. Someone just pointed out to me here at work that the crystal in their hands turned red after they turned 30 so maybe a nice metalic ruby red.
Title: Re: 1977 KZ400 Build
Post by: diesel450 on Dec 17, 2009, 12:54:04
With a silver fairing?!
Title: Re: 1977 KZ400 Build..."Logan's Run"
Post by: noahdog on Dec 17, 2009, 13:00:00
Maybe a couple of ankh symbols for sanctuary from the film on the side covers. ;)

(http://i486.photobucket.com/albums/rr226/noahnsteph/Ankh.jpg)
Title: Re: 1977 KZ400 Build "Logan's Run"
Post by: valvesprung on Dec 17, 2009, 23:54:25
I've long contemplated a fairing for my KZ, I'd love to see some full bike shots as soon as it's mocked up! I really want to get a feel for the whole picture. Nice work so far man, keep it up.
Title: Re: 1977 KZ400 Build "Logan's Run"
Post by: hillsy on Dec 18, 2009, 00:04:00
Not quite a full bike shot, but if you get the movie "STONE" you'll see some brand new Z1's with these fairings

(http://i428.photobucket.com/albums/qq6/hillsythegreat/PhotoID16411.jpg)
Title: Re: 1977 KZ400 Build "Logan's Run"
Post by: noahdog on Dec 18, 2009, 10:39:07
I love that paint job. Hmmmmmm 8)

I'm also thinking of removing all the badges and filling in the tank badge mounts before painting. I only have the KZ400 badge for one side cover anyway. I kinda like the idea of people having to take a close look to try and figure out what your bike is. ;)
Title: Re: 1977 KZ400 Build "Logan's Run"
Post by: diesel450 on Dec 18, 2009, 10:51:10
Cool paint job on that fairing! You could fade silver to red that would look wicked! That looks like EXACTLY the same fairing, too.
Title: Re: 1977 KZ400 Build "Logan's Run"
Post by: valvesprung on Dec 18, 2009, 13:38:38
Not quite a full bike shot, but if you get the movie "STONE" you'll see some brand new Z1's with these fairings

(http://i428.photobucket.com/albums/qq6/hillsythegreat/PhotoID16411.jpg)

Yeah I've seen them on the bigger bikes, I'm jsut concerened it will overwhelm my little 400...
Title: Re: 1977 KZ400 Build "Logan's Run"
Post by: noahdog on Dec 18, 2009, 13:56:11
I'll get some pics on wednesday even if I have to use some duct tape to hold in place. ;) Hopefully I'll get some mounting brackets fabbed up but I never know which part of the bike I'm gonna work on till the mood strikes. ;D 
Title: Re: 1977 KZ400 Build "Logan's Run"
Post by: diesel450 on Dec 18, 2009, 15:09:52
I think it looks good on your bike. The wind screen might need to be trimmed down a bit is all.
Title: Re: 1977 KZ400 Build "Logan's Run"
Post by: noahdog on Dec 31, 2009, 12:43:00
I've decided to make a new seat pan for my gas tank bum stop. I'm using some 3/4 OD tubing bent to match the bends on the frame and welding the rear part of the old gas tank to the new frame. Here's a pic of a quick mock up along with the 1/4 fairing on the front to give you a better idea of scale on the KZ400.

(http://i486.photobucket.com/albums/rr226/noahnsteph/KZ400%20Cafe%20Project/Bike.jpg)

Unfortunately it looks like I'm ditching the rear fender and I'll just use the license plate as a fender but I'm keeping the inner fender to protect from road debris and water. I'll probably hold on to the chrome rear fender for possible future projects since I do love the shape of the duck tail.
Title: Re: 1977 KZ400 Build "Logan's Run"
Post by: BadKaw on Dec 31, 2009, 17:47:50
Yup.  I think putting the duck-tail back on is the way to go.  The fairing looks "right"...paint will pull it all together.
Lookin' good!
-KR
Title: Re: 1977 KZ400 Build "Logan's Run"
Post by: diesel450 on Jan 01, 2010, 12:09:55
+1 ;D
Title: Re: 1977 KZ400 Build "Logan's Run"
Post by: beater on Jan 02, 2010, 11:57:21
i know this is against the grain, but out here in the rockies, I have come to love big arse screens. At least "double bubbles". We get really hammered by wind out here in the mountains, and a high screen makes all the difference. I'll take function over form any day.

j
Title: Re: 1977 KZ400 Build "Logan's Run"
Post by: noahdog on Jan 06, 2010, 18:22:35
Wow, now I know how not to cafe a KZ400. Check out this "cafe" on Ebay... http://cgi.ebay.com/ebaymotors/Kawasaki-kz400-kz400-cafe-racer-bobber-chopper-alloy-tank-no-reserve_W0QQcmdZViewItemQQhashZitem3ca8eb1b90QQitemZ260532018064QQptZUSQ5fmotorcycles
Title: Re: 1977 KZ400 Build "Logan's Run"
Post by: hillsy on Jan 06, 2010, 19:06:07
Wow, now I know how not to cafe a KZ400. Check out this "cafe" on Ebay... http://cgi.ebay.com/ebaymotors/Kawasaki-kz400-kz400-cafe-racer-bobber-chopper-alloy-tank-no-reserve_W0QQcmdZViewItemQQhashZitem3ca8eb1b90QQitemZ260532018064QQptZUSQ5fmotorcycles

That's a "fusion" bike. You know - cafe / bobber fusion....

He certainly has gone to a lot of effort to make it quite....ugly  ::)
Title: Re: 1977 KZ400 Build "Logan's Run"
Post by: noahdog on Jan 07, 2010, 13:35:55
I got the turn signals from Hong Kong finally and got them installed last night. I know they're very modern for a retro cafe but I think when it's all done it will givie the bike a cool 70's futuristic look.

(http://i486.photobucket.com/albums/rr226/noahnsteph/KZ400%20Cafe%20Project/P1060011.jpg)

(http://i486.photobucket.com/albums/rr226/noahnsteph/KZ400%20Cafe%20Project/P1060012.jpg)

(http://i486.photobucket.com/albums/rr226/noahnsteph/KZ400%20Cafe%20Project/P1060014.jpg)

The rear end will look much better once I get the tail light/plate holder installed. The license plate will act as a rear fender. I also finalized the plans for my seat frame. Now I just need some time to get it all cut and welded together.
Title: Re: 1977 KZ400 Build "Logan's Run"
Post by: noahdog on Jan 21, 2010, 17:39:23
After getting nothing done for what seems like weeks I finally got the frame for my seat welded up. Now  I just need to strip the paint off the gas tank rear end that I'm using for the bum stop and get it ready to weld on and bondo.

Here's some pics

(http://i486.photobucket.com/albums/rr226/noahnsteph/KZ400%20Cafe%20Project/P1200001.jpg)
(http://i486.photobucket.com/albums/rr226/noahnsteph/KZ400%20Cafe%20Project/P1200002.jpg)
(http://i486.photobucket.com/albums/rr226/noahnsteph/KZ400%20Cafe%20Project/P1200003.jpg)
(http://i486.photobucket.com/albums/rr226/noahnsteph/KZ400%20Cafe%20Project/P1200004.jpg)

The plan is to have snaps along the sides, across the bum stop and under the front lip to attach the cover once I get my wife to sew it for me. I also need to find a nice 1" closed cell foam for the padding.

I still need to cut out a template for the sheet metal top that I will weld to the top of the seat frame and make a plate for the back rest on the bum stop.
Title: Re: 1977 KZ400 Build "Logan's Run"
Post by: valvesprung on Jan 21, 2010, 18:59:07
Nice work man, looks great.
Title: Re: 1977 KZ400 Build "Logan's Run"
Post by: Gryph on Jan 21, 2010, 21:54:40
Looking real good, I toyed with the fairing idea for my KZ as well, I think it's going to look great.  Love the seat progress.

I haven't been on here for a while and it's nice to see all the KZ400s!
Title: Re: 1977 KZ400 Build "Logan's Run"
Post by: noahdog on Jan 22, 2010, 00:57:09
Looking real good, I toyed with the fairing idea for my KZ as well, I think it's going to look great.  Love the seat progress.

I haven't been on here for a while and it's nice to see all the KZ400s!

There does seem to be a recent outbreak of KZ400 projects around here lately. ;D  It's been very helpful checking out all the other builds.
Title: Re: 1977 KZ400 Build "Logan's Run"
Post by: 78kz on Jan 23, 2010, 22:29:55
Comming along nicely noah.
I also like to see some more KZs getting modded in this sea of Hondas. ;)
You'll appreciate having the fairing at speed.
I've had a few different ones on for a number of years.
Even started a season without one, but soon put it back on.
 8)
Title: Re: 1977 KZ400 Build "Logan's Run"
Post by: noahdog on Jan 24, 2010, 16:31:28
Got a little bit of work done. I got the sheet metal pan cut out and bent to fit the new seat frame and started stripping and sanding the gas tank bum stop.

(http://i486.photobucket.com/albums/rr226/noahnsteph/KZ400%20Cafe%20Project/P1240016.jpg)
Title: Re: 1977 KZ400 Build "Logan's Run"
Post by: noahdog on Jan 27, 2010, 23:58:56
More progress made tonight at our weekly bike night. We got the gas tank bum stop welded to the seat frame and the seat pan cut out to fit around the rear inner fender. I still need to cut out some more sheet metal for the back rest but I have the cardboard template cut out so I can get some more work done at home. I sold my stock seat on Ebay today and bought the new tail light with the proceeds. Should be here soon I hope. In the meantime I printed out and foam core mounted a color pic of the new tail light at work and did a quick mock up in 2 of the pics. I must say it looks pretty realistic in the pics. ;D

(http://i486.photobucket.com/albums/rr226/noahnsteph/KZ400%20Cafe%20Project/P1270018.jpg)
(http://i486.photobucket.com/albums/rr226/noahnsteph/KZ400%20Cafe%20Project/P1270022.jpg)
(http://i486.photobucket.com/albums/rr226/noahnsteph/KZ400%20Cafe%20Project/P1270020.jpg)
(http://i486.photobucket.com/albums/rr226/noahnsteph/KZ400%20Cafe%20Project/P1270021.jpg)

I may have to post a build thread over in the seat forum when this is all said and done. It's turning out exactly how I pictured it in my head which is freaky as hell. ;)

Title: Re: 1977 KZ400 Build "Logan's Run"
Post by: noahdog on Jan 28, 2010, 22:45:15
I brought the seat home with me last night so I could work on it here and amazingly enough I got some time to work on it. (doesn't hurt that the wife is out of town  ;)) I stopped by the neighborhood Harbor Freight (way too close to home for my wallet) and picked up a pop rivet gun and 100 assorted rivets on sale for $3.99 and got to work on getting the back rest done. I cut it out of the same sheet metal I used for the pan. Some small L-brackets riveted to the inside of the gas tank end to attach the back rest.

(http://i486.photobucket.com/albums/rr226/noahnsteph/KZ400%20Cafe%20Project/P1280023.jpg)
(http://i486.photobucket.com/albums/rr226/noahnsteph/KZ400%20Cafe%20Project/P1280024.jpg)
(http://i486.photobucket.com/albums/rr226/noahnsteph/KZ400%20Cafe%20Project/P1280025.jpg)

Title: Re: 1977 KZ400 Build "Logan's Run"
Post by: VonYinzer on Jan 29, 2010, 08:22:27
Looks good man!
Title: Re: 1977 KZ400 Build "Logan's Run"
Post by: noahdog on Feb 04, 2010, 00:40:24
My new tail light arrived in the mail today just in time for our weekly bike night.  ;D  After searching through the misc L-brackets & such laying around I found what I needed and made up a mounting bracket. I'm loving it so far especially when it's lit up. Here's some quick pics.

(http://i486.photobucket.com/albums/rr226/noahnsteph/KZ400%20Cafe%20Project/P2030002.jpg)
(http://i486.photobucket.com/albums/rr226/noahnsteph/KZ400%20Cafe%20Project/P2030001.jpg)
(http://i486.photobucket.com/albums/rr226/noahnsteph/KZ400%20Cafe%20Project/P2030005.jpg)

I still need to get some split loom or heat shrink to protect the wiring for the signals and tail ight and probably coat the underside of the bump with some truck bed liner spray.

I also got the mounting and latching mechanism for the seat all figured out tonight. I just need to bend some some steel rod and weld it up to line up to the factory seat lock and a couple of tabs at the front to go into the ends of the tube frame and I'm set. The cross brace in the tube frame fits exactly between the inner fender and the tool tray so there's no play front to back when the seat is sitting on the bike.
Title: Re: 1977 KZ400 Build "Logan's Run"
Post by: noahdog on Feb 11, 2010, 11:38:17
I got the latch mechanism sorted out last night for the seat. I'm using the factory seat lock to secure the new cafe seat using a piece of steel rod bent bent and welded to the seat frame that latches to the factory seat lock. I also got the seat pan welded to the frame once the mounting was all sorted out.Here some pics.

(http://i486.photobucket.com/albums/rr226/noahnsteph/KZ400%20Cafe%20Project/P2100006.jpg)
(http://i486.photobucket.com/albums/rr226/noahnsteph/KZ400%20Cafe%20Project/P2100007.jpg)
(http://i486.photobucket.com/albums/rr226/noahnsteph/KZ400%20Cafe%20Project/P2100011.jpg)
(http://i486.photobucket.com/albums/rr226/noahnsteph/KZ400%20Cafe%20Project/P2100013.jpg)
Title: Re: 1977 KZ400 Build "Logan's Run"
Post by: noahdog on Feb 18, 2010, 01:14:04
After spending 2 hours in the dentist chair this morning getting 3 crowns I decided to take the day off and work on the bike to take my mind off the pain.  ;)  I got the plates welded on to mount my new rearsets so now I'm on to sorting out the brake and shifter linkages. Unfortunately it look like the shifter linkage that came with the rearsets is too long so I 'll have to find a shorter one and I think I'll make a new brake rod from scratch from some 1/4" rod bent to form and threaded to fit  Here's some quick update pics.

(http://i486.photobucket.com/albums/rr226/noahnsteph/KZ400%20Cafe%20Project/P2170026.jpg)
(http://i486.photobucket.com/albums/rr226/noahnsteph/KZ400%20Cafe%20Project/P2170028.jpg)

My buddy Dave hard at work...
(http://i486.photobucket.com/albums/rr226/noahnsteph/KZ400%20Cafe%20Project/P2170027.jpg)

And the rearsets bolted to up to try them out for placement. They feel perfect.  ;D
(http://i486.photobucket.com/albums/rr226/noahnsteph/KZ400%20Cafe%20Project/P2170029.jpg)
(http://i486.photobucket.com/albums/rr226/noahnsteph/KZ400%20Cafe%20Project/P2170030.jpg)

They still need some touch up grinding and painting of course but I'm quite pleased overall.
Title: Re: 1977 KZ400 Build "Logan's Run"
Post by: thompsonmx100 on Feb 18, 2010, 01:21:21
You may be able to modify that shifter linkage. Might be worth throwing a pic up or at least describing it a little. If its just a rod you could cut it down and rethread it. If its a rod that the ends thread into you can cut it redrill it and tap it. keep it up.
Title: Re: 1977 KZ400 Build "Logan's Run"
Post by: noahdog on Feb 18, 2010, 09:18:15
Here's the stock pic from the ebay auction. It will at least give you an idea of what I'm working with till I can get a better close up pic posted.
(http://i486.photobucket.com/albums/rr226/noahnsteph/KZ400%20Cafe%20Project/rearset-dd-1.jpg)

The ends are threaded about an inch deep on each end so the only way I can think to shorten it would be to cut some off each end plus shorten the threads on the ball joints but I'm not sure if that will be enough and would leave me very little adjustment room even if it is short enough.
Title: Re: 1977 KZ400 Build "Logan's Run"
Post by: Kanticoy on Feb 18, 2010, 09:31:54
Those rearsets look great!  Keep it up man!
Title: Re: 1977 KZ400 Build "Logan's Run"
Post by: noahdog on Feb 18, 2010, 11:45:50
Oh yeah I forgot to mention a word of caution to the other KZ400 builders that the stock kicker won't clear the new rearsets when mounted where I put them. Fortunately another buddy has his CB550 in the garage as well so I borrowed his kick lever to see if it clears which it does but the grooves on the spline are a little different so I'll have to open it up nice and wide to slide onto the spline and then tighten it down. I'll probably pick up a CB550 kickstart lever sometime this week off Ebay. I'll post pics once I get it and get it on.
Title: Re: 1977 KZ400 Build "Logan's Run"
Post by: diesel450 on Feb 18, 2010, 12:14:08
Just a word of caution, you may be better off in the long run bending your stock kicker to clear rather than mounting a Honda kicker. If you strip that spline you will most likely have to change out the shaft and that is no small job.
Title: Re: 1977 KZ400 Build "Logan's Run"
Post by: noahdog on Feb 18, 2010, 12:25:24
My stock kicker already sticks out far enough to hit me in the shin and it still doesn't come close to clearing so it' gotta go. I'll need some kind of swing out kick lever like the CB550. My current one only has the foot peg hinged to swing out not the whole lever.
Title: Re: 1977 KZ400 Build "Logan's Run"
Post by: valvesprung on Feb 18, 2010, 14:45:34
The lever on the 78-79 KZ400a are different and will help to solve this problem. You may have to bend them a bit still, but they swing out like the honda, and they slip right on  ;)
Title: Re: 1977 KZ400 Build "Logan's Run"
Post by: noahdog on Feb 18, 2010, 14:58:22
Really? I'm off to Ebay then!  ;D
Title: Re: 1977 KZ400 Build "Logan's Run"
Post by: valvesprung on Feb 18, 2010, 17:50:04
Sorry the a after the KZ400 above was simply a typo, not a specific model needed...should be the same on all 78-79 KZ400's
Title: Re: 1977 KZ400 Build "Logan's Run"
Post by: noahdog on Feb 19, 2010, 16:00:14
Damn, I can't find a used 1978 kickstart lever to save my life. All I can find is NOS which is $145 & up!  :o  Do you guys think the splines would be the same on a KZ650 from the same year range? It looks very similair to the CB550 one I've been looking at for mock up as far as swing and size go.

Here's a pic of what I'm thinkig of buying...

(http://i486.photobucket.com/albums/rr226/noahnsteph/KZ400%20Cafe%20Project/KZ660Kicker.jpg)
Title: Re: 1977 KZ400 Build "Logan's Run"
Post by: beater on Feb 19, 2010, 20:09:51
steele's cycle salvage in denver.

Ask for bobby. tell him john henley sent you.
http://www.steelescycle.com/
Title: Re: 1977 KZ400 Build "Logan's Run"
Post by: noahdog on Feb 24, 2010, 23:48:58
Some progress and and a major catastrophe narrowly avoided tonight at bike night. I got the linkage set up for the shifter and was getting ready to move on to figuring the brake side when I asked my buddy Dave to hop on the bike to try the shifter for a second opinion. He weighs probably 30 lbs more than myself and when he was bouncing on the pegs checking the feel of the placement he tweeked the aluminum rearset brackets. I'd somewhat questioned the strength of them before but they'd held up to my weight although somewhat bouncy.  Since the mounting plates for the aluminum brackets  were already cut drilled and welded to the frame I was shitting twinkies. I decided to cut another plate to bolt through on the back of the welded plates that matched the profile of the aluminum brackets so I could have a 3 point mount instead of just the front bolts to eliminate any twisting in the aluminum brackets. I needed spacers for the foot peg bolt which is now the 3rd mounting point but it is solid as a rock now. Here's some pics to make some sense of my ramblings...

New plate.
(http://i486.photobucket.com/albums/rr226/noahnsteph/P2240030.jpg)

Brake side plate mounted.
(http://i486.photobucket.com/albums/rr226/noahnsteph/P2240029.jpg)

And a pic of my earlier success in completing the shift linkage which still counts since I just needed to add the new plate to strengthen the existing work. ;)
(http://i486.photobucket.com/albums/rr226/noahnsteph/P2240027.jpg)

I know there are a couple of other members here who have bought the same cheap universal rearsets as me on Ebay so I'd like to warn them to make the mounting plates big enough to bolt in all three places to avoid twisting. I'll try and search for who they were but hopefully they're following along and read this. I'm sure I've deleted the old pm's like a dummy. :-[
Title: Re: 1977 KZ400 Build "Logan's Run"
Post by: diesel450 on Feb 25, 2010, 00:38:30
So, uh, you got any of those twinkies??  :)
Title: Re: 1977 KZ400 Build "Logan's Run"
Post by: noahdog on Feb 25, 2010, 12:21:47
Nah,they went in the bucket with all the empty beer cans it took me to calm down and figure out how to fix the problem. ;)

All said I guess it's much better to find these problems in the garage than on the road.
Title: Re: 1977 KZ400 Build "Logan's Run"
Post by: Kanticoy on Feb 25, 2010, 12:36:30
Nah,they went in the bucket with all the empty beer cans it took me to calm down and figure out how to fix the problem. ;)

All said I guess it's much better to find these problems in the garage than on the road.

Amen to that man!

Looking good so far dude.  The rearsets look tits.
Title: Re: 1977 KZ400 Build "Logan's Run"
Post by: tWistedWheelz on Feb 25, 2010, 12:50:38
looking great man! Those rear sets are:
<sang in angelic tone> saweet! </sang in angelic tone>
Title: Re: 1977 KZ400 Build "Logan's Run"
Post by: noahdog on Feb 25, 2010, 13:13:53
I had a crazy thought last night after I mounted the backing plates for the rearsets. There's a 1/4" empty space between the rearsets and the back plate so I was thinking of mounting an amber LED to the back plate to illuminate behind the rearsets, shining through the opening in the aluminum brackets. My question is the legality of the lights. My thinking is as long as I use an amber LED wouldn't they just be "running lights"?  I was also thinking some LED arrays around the bike under the tank and behind the fairing to show off some shiny parts on the bike. 8)

This all started because my electrician buddy Dave added some blue 12V neon lights under the tank to light up his valve covers and carbs. We also removed the bulbs in his instrument clusters and soldered blue LEDs into the original light bulb bases to turn his gauges blue. It turned out sweet so I'll have to take some close up pics for the under $50 mod thread when we do mine. He also added a switch and blue LED indicator under the gauges for the under lighting.

What are your guy's thoughts?
Title: Re: 1977 KZ400 Build "Logan's Run"
Post by: tWistedWheelz on Feb 25, 2010, 13:20:04
This is just me, and I sometimes change my mind when I see something done tastefully, but I am not a fan of unessisary illumination on bikes! Its too.....fast and furious for my taste! It's ok for some fighters that are more show than go, but on the vintage ones, well, its just not for me. If you like it, go for it!

Cresent has talked about lights on his, and I think it will be sweet on his bike, but lets face it, his bike has created a whole new genre!
Title: Re: 1977 KZ400 Build "Logan's Run"
Post by: thompsonmx100 on Feb 25, 2010, 14:51:14
I too have thought of using lights under my tank and tail to show off the shiny bits. It will also help to add visibility at night. The rule of thumb is to not use blue red or white. but green and yellow should be ok. At the same time though I would check with your local laws. Its not a bad but needs to be tastefully done.
Title: Re: 1977 KZ400 Build "Logan's Run"
Post by: noahdog on Feb 28, 2010, 19:05:40
Got some more work done today on the bike.  I went to Home Depot and found a set of Irwin brand metric tap and dies so I was finally able to thread the steel rod I'd been planning on using for a brake linkage. The Harbor Freight set was crap and just stripped out but the Irwin set made quick work of threading the rod. A little torch action, some bending and voila we have brakes. ;)

(http://i486.photobucket.com/albums/rr226/noahnsteph/KZ400%20Cafe%20Project/P2280031.jpg)

The brake lever will even clear the exhaust once I cut off the mounting bracket and weld it further forward to bolt to the foot peg.  ;D

(http://i486.photobucket.com/albums/rr226/noahnsteph/KZ400%20Cafe%20Project/P2280034.jpg)

And here's a pic of the shifter side with the extra steel plate behind the rearset for stability.

(http://i486.photobucket.com/albums/rr226/noahnsteph/KZ400%20Cafe%20Project/P2280032.jpg)

Title: Re: 1977 KZ400 Build "Logan's Run"
Post by: beater on Feb 28, 2010, 19:39:55
where did you move your kickstand? I can't seem to find a place to move it to so it doesn't bother the shifer.

j
Title: Re: 1977 KZ400 Build "Logan's Run"
Post by: noahdog on Feb 28, 2010, 19:51:47
where did you move your kickstand? I can't seem to find a place to move it to so it doesn't bother the shifer.

j



I haven't welded it back on yet but so far the plan is to just weld it on futher forward on the frame, probably up near the very front. I still need to weld on some sort of catch for the center stand spring as well since that originally hooked to part of the passenger peg frame like the exhaust.  >:(
Title: Re: 1977 KZ400 Build "Logan's Run"
Post by: beater on Feb 28, 2010, 20:43:27
I took out the centerstand. that was 5lbs I won't miss. The kickstand is pretty far forward already, but I am in the same boat..
Title: Re: 1977 KZ400 Build "Logan's Run"
Post by: noahdog on Feb 28, 2010, 21:13:49
My bike was missing it so I actually picked up a center stand off Ebay when I decided to chop off the kick stand so I could keep working on the bike in an upright position. It may come back off when I'm all done and put a kick stand back on somewhere but for now it's quite handy to have the center stand.
Title: Re: 1977 KZ400 Build "Logan's Run" Color Decisions
Post by: noahdog on Mar 08, 2010, 20:09:16
So I'm trying to come up with a color for the bike. I'm leaning heavily towards a burgandy/wine color with a candy clear coat. There's an auto store near me that mixes Duplicolor paint to match standard auto color codes. After going through the color code PDF on the Duplicolor site I'm only finding one color that comes close to what I'm envisioning. It's a Dark Cherry Red by Hyundai which is ironic since my daily 4 wheel cage is a 2002 Hyundai Elantra. Here's the color, what are your thoughts?

(http://i486.photobucket.com/albums/rr226/noahnsteph/DarkCherryRedPaint.jpg)
Title: Re: 1977 KZ400 Build "Logan's Run"
Post by: Gryph on Mar 08, 2010, 21:32:55
Very classic, I love it.  Kinda wish I hadn't gone with plain ol' black on mine.  You gonna throw any stripes on there?
Title: Re: 1977 KZ400 Build "Logan's Run"
Post by: noahdog on Mar 09, 2010, 08:57:40
I'm kinda thinking of putting a silver stripe either down the middle of the tank and seat or maybe offset  a couple of inches to one side or the other.
Title: Re: 1977 KZ400 Build "Logan's Run"
Post by: diesel450 on Mar 09, 2010, 10:11:55
I like the color and the offset silver stripe idea. maybe one wide and one thin stripe?
Title: Re: 1977 KZ400 Build "Logan's Run"
Post by: noahdog on Mar 09, 2010, 12:51:37
Yeah, if I go offset I'm thinking maybe a half inch stripe next to a 2 inch one with 1/4-1/2" in between.
Title: Re: 1977 KZ400 Build "Logan's Run"
Post by: tWistedWheelz on Mar 09, 2010, 13:00:49
My suggestion would be an off-set stripe about 3-4 inches wide in a nice dark gray or charcoal with thin white pin stripes to boarder the transition! Should look great with that crimson! Black would look great as accents on that color as well, createing a nice 4 color scheme overall!
Title: Re: 1977 KZ400 Build "Logan's Run"
Post by: noahdog on Mar 09, 2010, 13:25:31
My suggestion would be an off-set stripe about 3-4 inches wide in a nice dark gray or charcoal with thin white pin stripes to boarder the transition! Should look great with that crimson! Black would look great as accents on that color as well, createing a nice 4 color scheme overall!

Pin stripes might be a little beyond my painting skills right now. :-[  This will be my first attempt at painting a bike with a spray gun and compressor. I did the SR250 restoration in all rattle cans which turned out pretty well but I probably spent more on spray paint than I would on cans of paint to run through the sprayer.
Title: Re: 1977 KZ400 Build "Logan's Run"
Post by: tWistedWheelz on Mar 09, 2010, 14:00:21
You don't have to hand stripe them, lay out your tape for gray stripe, lay the gray, then some clear, remove tape and wet sand, then lay out tape for both "pin stripes" on the transition area, spray white, clear, remove tape, wet sand, clear all again! Done!
Title: Re: 1977 KZ400 Build "Logan's Run"
Post by: noahdog on Mar 09, 2010, 16:16:27
That sounds do-able I guess. The next question is do I have the stripe down the fairing as well?
Title: Re: 1977 KZ400 Build "Logan's Run"
Post by: tWistedWheelz on Mar 09, 2010, 16:22:21
That sounds do-able I guess. The next question is do I have the stripe down the fairing as well?

Well its yours, you don't HAVE to do anything, but if it where mine, that stripe would continue over every paintable surface it crosses! Just makes for a more custom and nice look. Makes it like you left no detail unfinished!
Title: Re: 1977 KZ400 Build "Logan's Run"
Post by: noahdog on Mar 11, 2010, 09:13:57
Our weekly bike night was a complete cluster fuck this week. I was all excited since my new bar end mirrors were waiting for me in the mailbox when I got home but never got them installed. When I went to cut the end off my throttle grip I realized the throttle tube wasn't all the way onto the bars. This was a huge friggin problem since my brake master cylinder is already almost touching the handle bar risers as it is so there's no room to slide the throttle any further onto the bars. I then spent the rest of the night digging around for some old bars to chop up and some proper OD steel to use as slugs so I can add another couple of inches to the end of my bars and get everything welded on nice and straight. By the time I found all the parts I needed and starting cutting the old bars up for extensions it was too late and we'd had a few too many beers to start welding.  >:(  On the plus side the slugs I'm using should double as bar end weights to prevent some vibration. ;)  Hopefully we'll get the bars welded up this weekend and I'll get some pics taken and posted up for anyone else that might find themselves in the same boat.
Title: Re: 1977 KZ400 Build "Logan's Run"
Post by: noahdog on Mar 25, 2010, 00:30:02
Finally a productive bike night. Only one picture unfortunately of the handle bars after I welded extensions for some bar end mirrors. We also got the exhaust mount welded on so I could get it installed. Unfortunately I'd already taken apart all the controls so I could weld up the handle bars so I didn't get it started tonight but hopefully this weekend.

On top of a good night or progress I also found out I'm getting a new project bike.  I haven't seen it yet but my buddy who found it says it's a Kawasaki 400 triple so it sounds like it could be a unique project.  I don't know what year or condition yet but I'm never one to turn down a free bike. ;)  Hopefully I'll get it picked up on sunday and I'll get some pics posted.

Anyway here's the one photo I got tonight of one side of the handle bar extension.

(http://i486.photobucket.com/albums/rr226/noahnsteph/KZ400%20Cafe%20Project/P3240036.jpg) (http://s486.photobucket.com/albums/rr226/noahnsteph/KZ400%20Cafe%20Project/?action=view&current=P3240036.jpg)
Title: Re: 1977 KZ400 Build "Logan's Run"
Post by: thompsonmx100 on Mar 25, 2010, 00:57:35
so seamless I couldn't even tell you had don anything. Looks good.
Title: Re: 1977 KZ400 Build "Logan's Run"
Post by: gribbs on Mar 25, 2010, 01:18:05
I am 6' 2" and those rear-set locations look sooo gravy!! I cant wait to make some up just like that
Title: Re: 1977 KZ400 Build "Logan's Run"
Post by: gizmoe639 on Mar 25, 2010, 04:37:38
Hey man i was just curious how exactly you got the bend on the front ''cross bar" on your  seat pan. It looks really nice.
Title: Re: 1977 KZ400 Build "Logan's Run"
Post by: noahdog on Mar 25, 2010, 08:50:40
Hey man i was just curious how exactly you got the bend on the front ''cross bar" on your  seat pan. It looks really nice.

That front cross bar is actually a piece of electrical conduit since the steel tubing I was using for the rest of the seat was too stiff to bend in such a short span. I bent the conduit in the pipe bender then flattened the ends with the bench vice and cut the ends at an angle with the angle grinder and a cut off wheel to give the cross bar a slight forward lean when welded to the rest of the seat frame.

Title: Re: 1977 KZ400 Build "Logan's Run"
Post by: valvesprung on Mar 25, 2010, 13:05:44
Oh man, from one KZ enthusiast to another, the KH400 triple is definitely at the top of my list for the next project...such sweet little scoots...
Title: Re: 1977 KZ400 Build "Logan's Run"
Post by: noahdog on Mar 25, 2010, 13:46:48
Oh man, from one KZ enthusiast to another, the KH400 triple is definitely at the top of my list for the next project...such sweet little scoots...

Yeah the more I research them the more excited I am to go pick it up.  Not much in the way of parts on Ebay for them though. I can get brand new stock pistons and rings for $70 or so with shipping.  ;D  Might have to rethink the SR250 bobber project next winter and do the KH400 instead.
Title: Re: 1977 KZ400 Build "Logan's Run"
Post by: klx678 on Mar 25, 2010, 13:57:04
Yeah the more I research them the more excited I am to go pick it up.  Not much in the way of parts on Ebay for them though. I can get brand new stock pistons and rings for $70 or so with shipping.  ;D  Might have to rethink the SR250 bobber project next winter and do the KH400 instead.

I had the earlier version S3 400 triple, 1975.  With a set of chambers they have the sweetest burble, far better than any twin two stroke.  With the standard gear pattern and rubber mounted engine they were great rides.  They'd smoke anything short of an RD.  None of the 550 and smaller four strokes could touch them.  I wish I still had mine.
Title: Re: 1977 KZ400 Build "Logan's Run"
Post by: noahdog on Mar 26, 2010, 17:48:31
The wives went out to the bar for a girls night last night so my buddy Dave and I decided to have an impromptu 2nd bike night of the week. I got the rest of my handle bar extensions smoothed out and mounted along with the new bar end mirrors. I also got the exhaust bolted back on and got to fire the bike up for the first time this year. ;D The exhaust has been off the last couple of months while I chopped the frame and added rearsets. She surprisingly fired right up even after sitting for over 3 months. Now I need to get the new signals all wired up and get prepped for paint. I should be riding again in a couple of weeks.  I'll probably take it for a spin around the neighborhood next wednesday with or without signals so I can get my fix in before I pull the tank and empty it to get it ready for paint.

Title: Re: 1977 KZ400 Build "Logan's Run"
Post by: noahdog on May 06, 2010, 17:57:23
I know I know, I haven't updated in forever but there hasn't been much to update. I finally got a chance to take the bike for spin to check the positioning of the new rearsets and handle bars. I like the riding position with the new rearsets but I gotta say the handle bars SUCK!!! The only way I could get the master cylinder to clear the fairing without bottoming out on the top of the shocks was to have the drag bars pointing down which put unbearable pressure on the hands between the thumb and forefinger. I'm afraid the only way to keep the fairing and still use my stock brake master cylinder is either absolutely straight drag bars or some adjustable clip ons like these.... http://www.fastfromthepast.com/servlet/the-738/Clip-dsh-on-High-Rise-Handlebars/Detail  The straight bars are much cheaper but I really like the clip ons and I think they would be much more comfortable. I guess I need to sell some more parts so I can afford the Tarozzi clip ons. :(