DO THE TON

Blood Sweat Tears and Grease => Projects => Cafe Racers => Topic started by: MILLENNIUM FALCON on Feb 23, 2011, 09:57:05

Title: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Feb 23, 2011, 09:57:05
This is my 78 kz400 6-speed cafe build. I bough this bike for $100 awhile ago but just started working on it. I am working on some rearsets and clip ons. I already drilled the rotor and started working on the seat. I just started stripping and mounting the 72' cb350f tank. I tried my hand at knee dents and it went pretty well. The tank had alot of other dents before I started. I will try to post pictures as I go.(http://i1080.photobucket.com/albums/j336/captain_neto/011-2.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/006-7.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/005-6.jpg)
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Feb 23, 2011, 09:58:43
The tank will sit flat once its mounted, but right now it wont slide over the stock kawasaki mounts.
Title: Re: 78 kz400 cafe build
Post by: treitz on Feb 23, 2011, 11:44:57
Another 400. Awesome! There a ton of KZ's poppin up on here lately.

It's a fun bike, keep us posted!
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Feb 23, 2011, 20:19:52
I just finished mounting the tank. I think it will look much more vintage than the stock tank. I used a slide hammer to get out most of the old dents. I started smoothing out my knee dents with fiberglass filler.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Feb 26, 2011, 18:26:07
I cut out the blanks for my ankle gaurds and mounted them. I put c-clamps on them to act as pegs to figure out where I was going to mount them. I got everything mounted. Now I just need turn and knurl the pegs once I part them to length. I dont know If I want to mill slots in my ankle gaurds or come up with a pattern of holes to make it look good and loose some weight. either way I will be polishing everything once its done. So far so good.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Feb 26, 2011, 18:27:52
C-clamp peg (temporary) It did feel pretty good though.  ;)
Title: Re: 78 kz400 cafe build
Post by: Epic retry on Feb 26, 2011, 18:33:32
looking good
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Mar 02, 2011, 11:26:24
Just finished the other side. Now Im starting the controls.
Title: Re: 78 kz400 cafe build
Post by: reelinfeele on Mar 02, 2011, 12:16:29
very nice dude. i like the speed holes. keep it up
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Mar 02, 2011, 12:58:14
I set the engine in the frame so I can get my shift linkage figured out.
Title: Re: 78 kz400 cafe build
Post by: MotorbikeBruno on Mar 02, 2011, 13:10:12
Very cool. I've got a stock 80' KZ440 and I may just have to start cutting it up now...dang you!
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Mar 02, 2011, 13:46:37
it is contageous you know!
Title: Re: 78 kz400 cafe build
Post by: valvesprung on Mar 02, 2011, 15:12:35
Very cool man. I'd be interested in a set of the rear sets without the speed holes, for my KZ400 (though a bit down the road) Sounds like a couple other guys may too if you're up for it.

Have you figured out a good brake linkage yet? Do they clear the kick start lever as they are? I have a '77 which has a much crappier lever for fitment and was told the 78-79 lever was better for this...
Title: Re: 78 kz400 cafe build
Post by: stik70 on Mar 02, 2011, 18:34:32
this is going to be a beautiful bike. Your workmanship is superb. Can't wait to see more progress!
Kev
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Mar 03, 2011, 09:58:11
Yeah I will see how these turn out. As long as I have time, I would gladly make a few more. Send me a pm when you are ready.
 
 
Very cool man. I'd be interested in a set of the rear sets without the speed holes, for my KZ400 (though a bit down the road) Sounds like a couple other guys may too if you're up for it.

Have you figured out a good brake linkage yet? Do they clear the kick start lever as they are? I have a '77 which has a much crappier lever for fitment and was told the 78-79 lever was better for this...
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Mar 03, 2011, 09:59:08
Thanks, I am really excited with how things are coming together.
 
this is going to be a beautiful bike. Your workmanship is superb. Can't wait to see more progress!
Kev
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Mar 03, 2011, 10:06:12
All I had to do for the brake linkage was flip the lever on the drum, so it runs above the swing arm. Its not completely done yet, but It should attatch to my new brake arm with little or no bend. I will have to widen the clevis on the end because my new lever is 1/4" and the stocker was more like 12ga sheet metal. I will get you some pictures once I get it all hooked up.
 
 
Very cool man. I'd be interested in a set of the rear sets without the speed holes, for my KZ400 (though a bit down the road) Sounds like a couple other guys may too if you're up for it.

Have you figured out a good brake linkage yet? Do they clear the kick start lever as they are? I have a '77 which has a much crappier lever for fitment and was told the 78-79 lever was better for this...
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Mar 03, 2011, 10:09:51
Oh yeah.....the peg clears the kicker by almost 2" on the side and about and 1" behind" As long as your not starting the bike with snow shoes on it should be fine. This was very important to me because I plan on making this bike kick only. 
 
Very cool man. I'd be interested in a set of the rear sets without the speed holes, for my KZ400 (though a bit down the road) Sounds like a couple other guys may too if you're up for it.

Have you figured out a good brake linkage yet? Do they clear the kick start lever as they are? I have a '77 which has a much crappier lever for fitment and was told the 78-79 lever was better for this...
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Mar 03, 2011, 17:11:21
 Here it is. There is a split on the side but if you just need the pan i guess it doesnt matter. My internet at home is out so it might be a few days before I can check pm's, but let me know.
Title: Re: 78 kz400 cafe build
Post by: treitz on Mar 03, 2011, 19:30:13
Thanks man. I'll get back to you after I see what exactly I want to do.

Tyler
Title: Re: 78 kz400 cafe build
Post by: treitz on Mar 04, 2011, 11:17:02
Think I've just decided to roll with the seat I have for now. Thanks for posting that for me.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Mar 05, 2011, 13:23:36
No problem man....good luck
 
Think I've just decided to roll with the seat I have for now. Thanks for posting that for me.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Mar 05, 2011, 13:33:53
The brake side is done
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Mar 05, 2011, 13:37:27
Some more pics
Title: Re: 78 kz400 cafe build
Post by: valvesprung on Mar 05, 2011, 13:58:00
Looks great!
Title: Re: 78 kz400 cafe build
Post by: MotorbikeBruno on Mar 05, 2011, 14:13:49
Well done man! Those look great! 
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Mar 05, 2011, 19:34:34
Full body shot 8)
Title: Re: 78 kz400 cafe build
Post by: biker_reject on Mar 05, 2011, 21:32:45
Did you experience any flex in your levers?  I finally completed the linkage to my home made rearsets and discovered that they flex alot!  I will have to start from scratch and go with at least 3/8" aluminum.  I can really kick myself for not buying pre-made rear sets in the first place.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Mar 06, 2011, 14:21:02
They seem stiff so far. They should be much stronger than the stock levers. I will find out when I get her on the road.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Mar 09, 2011, 13:47:05
I'm back  at it. I just finished the shifter side.
Title: Re: 78 kz400 cafe build
Post by: valvesprung on Mar 09, 2011, 14:13:27
Looks fantastic, nice work man.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Mar 11, 2011, 01:36:00
Now I need to figure out my exhaust and bars. I was thinking of using the stock header pipes to go 2-1 into a silencer out the right side at an angle. I just need to find a pipe. Any ideas? I also can't decide if I want to go with clip ons or clubmans. What do you guys think?
Title: Re: 78 kz400 cafe build
Post by: MotorbikeBruno on Mar 11, 2011, 15:13:06
Any particular look (for the silencer that is)  like GP style, polished, etc?  You could find the pipe and then fab up some connections to it. 

http://cgi.ebay.com/ebaymotors/motorcycle-stunt-bike-short-muffler-slip-on-/200572257548?pt=Motorcycles_Parts_Accessories&hash=item2eb309c50c (http://cgi.ebay.com/ebaymotors/motorcycle-stunt-bike-short-muffler-slip-on-/200572257548?pt=Motorcycles_Parts_Accessories&hash=item2eb309c50c)

Not saying you should go with this, but it came up in a search.
Title: Re: 78 kz400 cafe build
Post by: Syke on Mar 11, 2011, 15:28:43
Now I need to figure out my exhaust and bars. I was thinking of using the stock header pipes to go 2-1 into a silencer out the right side at an angle. I just need to find a pipe. Any ideas? I also can't decide if I want to go with clip ons or clubmans. What do you guys think?

I'll toss a vote in for the clubmans.  Admittedly, it's more a personal preference and historical accuracy (back in the day clips ons were way more expensive than clubmans) than any functional advantage.
Title: Re: 78 kz400 cafe build
Post by: biker_reject on Mar 11, 2011, 15:56:18
I like clip-ons.  With the narrow profile of the KZ, I think clubmans would be too wide, comically so.  Of course, I'm not really concerned with achieving historical accuracy.
Title: Re: 78 kz400 cafe build
Post by: treitz on Mar 11, 2011, 22:28:01
I have a Harley sportster mufflers on mine. They look pretty cool and people practically give them away. Although they are pretty quiet until you really open it up.

You can see and hear them in my build thread.
Title: Re: 78 kz400 cafe build
Post by: valvesprung on Mar 11, 2011, 22:38:39
The Norton seamless peashooters on my KZ just simply rip. I love the sound. Deep and throaty at idle, with that gnarly Britist type rasp at high RPM. Not for the faint of heart, but quieter and less droney than m custom baffle set up before it.

They go for $130/pair on Ebay and I think Dime City has them now too. We simply cut off the stock mufflers, welded these on, slipped the little heat sheilds back on over the seam, and I bent two extremely simple brackets from 1/8" flat bar and bolted through the passenger peg brackets...

If you like some serious bite from your exhaust you will love these...not TOOOOOO loud though :)
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Mar 11, 2011, 23:30:37
I would like a gp style pipe to come out under the right peg. I was thinking about wrapping the headers and having a chrome silencer/tip
Any particular look (for the silencer that is)  like GP style, polished, etc?  You could find the pipe and then fab up some connections to it. 

http://cgi.ebay.com/ebaymotors/motorcycle-stunt-bike-short-muffler-slip-on-/200572257548?pt=Motorcycles_Parts_Accessories&hash=item2eb309c50c (http://cgi.ebay.com/ebaymotors/motorcycle-stunt-bike-short-muffler-slip-on-/200572257548?pt=Motorcycles_Parts_Accessories&hash=item2eb309c50c)

Not saying you should go with this, but it came up in a search.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Mar 11, 2011, 23:59:35
The price of clubmans is very attractive.
I'll toss a vote in for the clubmans.  Admittedly, it's more a personal preference and historical accuracy (back in the day clips ons were way more expensive than clubmans) than any functional advantage.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Mar 12, 2011, 00:21:40
Yeah They do look and sound sweet. Thanks
 
I have a Harley sportster mufflers on mine. They look pretty cool and people practically give them away. Although they are pretty quiet until you really open it up.

You can see and hear them in my build thread.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Mar 12, 2011, 01:27:46
I will have to look into that. did you just grind off the chrome to weld it?
 
The Norton seamless peashooters on my KZ just simply rip. I love the sound. Deep and throaty at idle, with that gnarly Britist type rasp at high RPM. Not for the faint of heart, but quieter and less droney than m custom baffle set up before it.

They go for $130/pair on Ebay and I think Dime City has them now too. We simply cut off the stock mufflers, welded these on, slipped the little heat sheilds back on over the seam, and I bent two extremely simple brackets from 1/8" flat bar and bolted through the passenger peg brackets...

If you like some serious bite from your exhaust you will love these...not TOOOOOO loud though :)
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Mar 12, 2011, 01:45:03
I cut my stock headers and turned them in, now I need to make a collector and figure out where I want it to come out. It looks like I will be removing the center stand...oh well It will shave a few more pounds. HAs anyone made their own collector? If so what did you use? Sorry the pictures are a little blurry, but you get the picture.
Title: Re: 78 kz400 cafe build
Post by: treitz on Mar 12, 2011, 11:47:18
As far as bars go, just buy some clubmans and throw them on there. If you love them, keep em. If you don't, keep your eye out for a great deal on some clipons. Thats what I did at least.

Honestly I liked them both. The clubmans (IMO) give the bike more a vintage look while the clipons give it more of a modernish race bike look.

In my build you can see my bike with both sets of bars on it for reference.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Mar 12, 2011, 15:45:36
That is a good idea I can get a set of clubmans for $20 if I dont like them, its not much of a loss.
 
As far as bars go, just buy some clubmans and throw them on there. If you love them, keep em. If you don't, keep your eye out for a great deal on some clipons. Thats what I did at least.

Honestly I liked them both. The clubmans (IMO) give the bike more a vintage look while the clipons give it more of a modernish race bike look.

In my build you can see my bike with both sets of bars on it for reference.
Title: Re: 78 kz400 cafe build
Post by: Epic retry on Mar 12, 2011, 15:51:35
 good morning . your bike is realy turning out nice ! the rear sets would make your grandfather very happy. Just came in from a ride .when you wanna go?
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Mar 12, 2011, 18:27:12
That was a good first ride! No one broke down or wrecked, I hope it will be a little warmer next time. then we can go farther.
 
 
good morning . your bike is realy turning out nice ! the rear sets would make your grandfather very happy. Just came in from a ride .when you wanna go?
Title: Re: 78 kz400 cafe build
Post by: Erskine on Mar 12, 2011, 18:51:22
I like your rearsets, I'm going to have to drill mine out some time, yours are a good counterpoint.
Nice build btw, it's reassuring to see another one not trying to be pristine from the onset.
Title: Re: 78 kz400 cafe build
Post by: VonZipper on Mar 12, 2011, 19:55:49
I've got some nice Clubman's I'm not going to use if you are interested in them PM me.  VZ
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Mar 12, 2011, 21:04:03
Thank you. I'm going for the vintage look, but not accurate or restored origional.
 
I like your rearsets, I'm going to have to drill mine out some time, yours are a good counterpoint.
Nice build btw, it's reassuring to see another one not trying to be pristine from the onset.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Mar 12, 2011, 21:05:27
I would love to have shown him. It feels good to use his tools. PS you need to get a profile picture. ::)
 
good morning . your bike is realy turning out nice ! the rear sets would make your grandfather very happy. Just came in from a ride .when you wanna go?
Title: Re: 78 kz400 cafe build
Post by: treitz on Mar 12, 2011, 23:49:20
Exactly, clubmans are cheap. And if your lucky you can resell them for what you paid for them down the road if you want to.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Mar 15, 2011, 00:30:08
I have decided to go with clip-ons. I am cheap so I am going to machine them myself. I got out some aluminum and started brain storming. I cant decide how I want to do this. Any Idea's?
Title: Re: 78 kz400 cafe build
Post by: treitz on Mar 15, 2011, 00:35:18
Good luck! Wish I had the tools and abilities to machine things like that.

Look forward to seeing what you come up with!
Title: Re: 78 kz400 cafe build
Post by: Dale on Mar 15, 2011, 02:33:02
I have decided to go with clip-ons. I am cheap so I am going to machine them myself. I got out some aluminum and started brain storming. I cant decide how I want to do this. Any Idea's?

If it were me - I would make the clamps from 40mm thick alli - the profile simply having the same diameter round cutout as your forks. Then a cross cut probably around 2-3 mm wide into one side. Drill across your cross cut and tap. This would form the bases of a clamp. Then get alli tubing and tap into the side of the 40mm clamp. This would form the bars. A bit of work, but really quite doable... Very cool -  looking forward to seeing what you come up with...
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Mar 15, 2011, 07:53:44
Thanks for the input. There really aren't many DIY clips ons out there.
 
 
If it were me - I would make the clamps from 40mm thick alli - the profile simply having the same diameter round cutout as your forks. Then a cross cut probably around 2-3 mm wide into one side. Drill across your cross cut and tap. This would form the bases of a clamp. Then get alli tubing and tap into the side of the 40mm clamp. This would form the bars. A bit of work, but really quite doable... Very cool -  looking forward to seeing what you come up with...
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Mar 16, 2011, 23:15:09
Sorry guys I know I have been slacking on this build. I wish I had more time to work on the kz. This has been a crazy week. I'll get back at her as soon as I can.
Title: Re: 78 kz400 cafe build
Post by: DoubleL3 on Mar 17, 2011, 01:31:49
For the clip-ons, it might be hard to machine in a downward angle for the bars, since that is probably what will be more comfortable. Depending on your machining equipment it could be quite simple, I have machined some parts with crazy angles in them on a manual mill before with nothing other than a digital protractor. I mention this because I am also looking into building my own set of clip-ons, though I am planning on going with the steel/weldment fabrication method since thats what I find easier and more robust. Would love to see how yours come out since I am working on KZ550.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Mar 17, 2011, 10:04:23
I have an angle vise and a indexing compound head mill so the angle shouldn't be a problem. I also thought about making a straight hole through my clamp and just putting a bend on the end of my bars like ROC CITY CAFE's adjustable clips ons are built. That would be the easy way, I just need to make up my mind on how I want to do it. I havnt really had any time to sit down and lay it out. Let me know how your 550 comes out.
 
 
For the clip-ons, it might be hard to machine in a downward angle for the bars, since that is probably what will be more comfortable. Depending on your machining equipment it could be quite simple, I have machined some parts with crazy angles in them on a manual mill before with nothing other than a digital protractor. I mention this because I am also looking into building my own set of clip-ons, though I am planning on going with the steel/weldment fabrication method since thats what I find easier and more robust. Would love to see how yours come out since I am working on KZ550.
Title: Re: 78 kz400 cafe build
Post by: DoubleL3 on Mar 17, 2011, 20:49:12

I wish I had a mill with the cool vises and tools... I have used them before but I don't have unlimited access for my projects.

When I finish the dual front disc conversion Ill start a thread on it, I just havent had the time with a camera to take any glamour shots  ;D
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Mar 17, 2011, 21:09:29
Finaly started milling things down. I got the stock roughed out. I will start boring holes tomorrow.
Title: Re: 78 kz400 cafe build
Post by: valvesprung on Mar 17, 2011, 22:54:19
Color me extremely interested in the dual disc conversion :)
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Mar 18, 2011, 01:56:42
Ok I got the holes bored out. I decided to put the angle on my bars rather than the clamps just to keep things simple. I still have a bit of material to remove and some tapping to do but they are coming along.
Title: Re: 78 kz400 cafe build
Post by: reelinfeele on Mar 18, 2011, 10:15:23
very cool.
Title: Re: 78 kz400 cafe build
Post by: treitz on Mar 18, 2011, 11:53:19
Nice work!
Title: Re: 78 kz400 cafe build
Post by: teazer on Mar 18, 2011, 13:00:11
Try these for inspiration

http://www.woodcraft-cfm.com/cgi-bin/commerce.cgi?search=action&category=OOOX (http://www.woodcraft-cfm.com/cgi-bin/commerce.cgi?search=action&category=OOOX)


https://www.vortexracing.com/shop/category/17/83/ (https://www.vortexracing.com/shop/category/17/83/)


http://www.clubmanracing.com/handlebarsandlevers.php (http://www.clubmanracing.com/handlebarsandlevers.php)

Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Mar 18, 2011, 22:05:50
I dont think mine will look that fancy but they should do the same job. Thanks for the input. I hope they turn out.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Mar 20, 2011, 01:47:30
This seem to be the slowest part of my build! (I hope) :P  I Spent about 3 hours catching up the right clamp. now I am trying to decide If I want to start hoging off material or keep it big beefy and strong looking. Once I get the clip ons done, I will be moving back to the frame. I need to get the wiring and exhaust figured out, I also need to get my seat mounted. I am trying to get all my chassis mods done so I can get my frame painted. Still so much work to do.
Title: Re: 78 kz400 cafe build
Post by: DoubleL3 on Mar 20, 2011, 01:58:45
I'd say leave them big but put some nice big fillets on the areas that aren't structural to give it a nice flowing and strong look, especially if you are planning on running the stock curvy tank.
Title: Re: 78 kz400 cafe build
Post by: biker_reject on Mar 20, 2011, 03:34:47
These are my Pro Flo clip-ons, an awesome dbay score.  I love the beefiness of these things.  Perhaps they'll give you some ideas.
(http://i133.photobucket.com/albums/q56/El_NiNo_album/clusterandfairingstay.jpg)
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Mar 22, 2011, 02:46:47
I Just about finished the left side clamp tonight. I have a few finishing touches to take care of then, I'm moving on to the right side. I decided to go with the beefy look. (just in case you were wondering)
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Mar 22, 2011, 10:07:15
I still might bevel/round the edges. Does anyone know where to get wheels and spoke kits for kz400's?
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Mar 22, 2011, 18:58:59
I was thinking about putting a 45 on the outside edges, or do you think I should just leave it as is?
 
 
I still might bevel/round the edges. Does anyone know where to get wheels and spoke kits for kz400's?
Title: Re: 78 kz400 cafe build
Post by: Epic retry on Mar 22, 2011, 20:40:13
Hello! This is really turning out nice . Alway like to see someones ideas . take your time and you will be happy with the results keep up the good work
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Mar 23, 2011, 18:44:29
We have a pair! finally! I still need to get some bars and slide them in. I'm didnt mount them because I dont feel like pulling the forks at the moment.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Mar 23, 2011, 18:45:15
a few more pics
Title: Re: 78 kz400 cafe build
Post by: Erskine on Mar 23, 2011, 19:00:48
They've turned out really well, look strong too.
I'd soften the edges once you know they are right.
Title: Re: 78 kz400 cafe build
Post by: chilli on Mar 23, 2011, 19:04:24
I was thinking about putting a 45 on the outside edges, or do you think I should just leave it as is?
 

I'd say put a bevel on if you can, you've done the work to make it functional but you'll really appreciate the extra finish later.

I just wish I had the skills/tools do get that far!
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Mar 24, 2011, 01:14:32
Ok i took your advice and beveled the edges where I could. It gives it a smooth look.......I like it.
Title: Re: 78 kz400 cafe build
Post by: Erskine on Mar 24, 2011, 06:21:17
Yup, that's a big visual improvement. I wish I had the kit to bang stuff out like that!
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Mar 24, 2011, 08:13:34
 I would have gone all the way around the clamp but, the taper would have run into my holes and I didnt want that.
 
Yup, that's a big visual improvement. I wish I had the kit to bang stuff out like that!
Title: Re: 78 kz400 cafe build
Post by: DoubleL3 on Mar 26, 2011, 23:27:31
Those turned out really nice. The bevels definitely enhance the look and add to the beefiness.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Mar 28, 2011, 23:11:20
I just ordered my exhaust. The plan is to go 2-into-1 exet at a steep angle just behind the right rear-set. I am using the stock header pipes; they will get painted with hi-temp and wrapped with black header wrap. I need to fab up a collector and a mount.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Mar 28, 2011, 23:14:29
I forgot to say.......I chose the 17" shorty reverse megaphone from dime city cycles. This was the first cent I have spent on this bike other than the purchase price of $100. I knew this build would require money eventually.
 
I just ordered my exhaust. The plan is to go 2-into-1 exet at a steep angle just behind the right rear-set. I am using the stock header pipes; they will get painted with hi-temp and wrapped with black header wrap. I need to fab up a collector and a mount.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Apr 02, 2011, 17:08:15
Ok... its been awhile but I finally got my exhaust mocked up. I made a collector. I still need to make a hanger and weld my exit pipe into the collector. I will be wrapping everything in black header wrap all the way back to the muffler.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Apr 02, 2011, 17:09:07
a few more pics
Title: Re: 78 kz400 cafe build
Post by: valvesprung on Apr 02, 2011, 20:16:28
Lines look great man, really dig it. Bet it'll sound great.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Apr 02, 2011, 20:48:55
Thanks, I hope it sounds good. Its been so long since I started this project I dont remember what it used to sound like. Do you have any ideas/inspiration for a tail light setup?
 
 
Lines look great man, really dig it. Bet it'll sound great.
Title: Re: 78 kz400 cafe build
Post by: valvesprung on Apr 02, 2011, 23:44:24
It's tough to find good options with cafe tails, but I like just using red tinted dual filament turn signals to do both jobs :) Harley uses this method on the 883 Iron and Nightster. Dime City sells some nice alloy dual fil turns, get a can of Testors Transparent Candy Apple Red in a spray can from a hobby shop and tint away
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Apr 03, 2011, 08:21:31
Do you have any pictures of that setup on a bike? (I'm a visual learner)
 
It's tough to find good options with cafe tails, but I like just using red tinted dual filament turn signals to do both jobs :) Harley uses this method on the 883 Iron and Nightster. Dime City sells some nice alloy dual fil turns, get a can of Testors Transparent Candy Apple Red in a spray can from a hobby shop and tint away
Title: Re: 78 kz400 cafe build
Post by: Erskine on Apr 03, 2011, 10:38:03
Lines look great man, really dig it. Bet it'll sound great.

+1 :)
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Apr 04, 2011, 17:45:03
I finished welding up my exhaust. It still needs wrapped. One step closer to painting the frame.
Title: Re: 78 kz400 cafe build
Post by: treitz on Apr 04, 2011, 17:47:57
I like it. Cool how it kicks out to the side and up.

Making my exhaust 2-1, or buying the 2-1 header from the local salvage yard is on my down the road list as well.
Title: Re: 78 kz400 cafe build
Post by: MotorbikeBruno on Apr 04, 2011, 20:57:11
someone was looking for inspiration on tails and lights... thought I would toss this up for you if you haven't seen it.

http://www.dotheton.com/forum/index.php?topic=14127.0;topicseen (http://www.dotheton.com/forum/index.php?topic=14127.0;topicseen)
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Apr 04, 2011, 22:22:45
Thanks, that thread has tons of great Ideas.
 
someone was looking for inspiration on tails and lights... thought I would toss this up for you if you haven't seen it.

http://www.dotheton.com/forum/index.php?topic=14127.0;topicseen (http://www.dotheton.com/forum/index.php?topic=14127.0;topicseen)
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Apr 06, 2011, 21:07:15
My new battery came today. It will be going inside my seat. Its a 12v 6.0 amp hour. 
Title: Re: 78 kz400 cafe build
Post by: Jonny on Apr 06, 2011, 22:40:29
thats ether one really big one dollar bill! or a really sweet battery :)
Title: Re: 78 kz400 cafe build
Post by: Jonny on Apr 06, 2011, 22:42:32
Nice job on the bike thus far!
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Apr 06, 2011, 23:07:40
That is an acual US 1 dollar bill I stole from my wife's purse. (for size comparison)
 
 
 
Nice job on the bike thus far!
Title: Re: 78 kz400 cafe build
Post by: Jonny on Apr 06, 2011, 23:09:45
hahaha thats awesome :), where did you pick up the battery from? if you dont mind me asking
Title: Re: 78 kz400 cafe build
Post by: jeffreyhardy on Apr 06, 2011, 23:10:18
My new battery came today. It will be going inside my seat. Its a 12v 6.0 amp hour.
that's badass. I wonder if it would hold up for my cl350?
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Apr 06, 2011, 23:39:21
I got it from mcmaster carr. They have tons of different batteries, just find the right voltage/amp/size They are really reasonable too. This one was under $25 bucks. The place I used to work used them all the time for computer UPS systems (uninterupped power source) They are pretty sweet! Completely sealed and matinence free. You can mount them in any position and they are ment to be charged and drained 100s of times so they last for ever.  My bike is goin to be kick only so it only has to power the lights and ignition. I dont think this would be a battery for running electric start.
 
hahaha thats awesome :) , where did you pick up the battery from? if you dont mind me asking
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Apr 06, 2011, 23:41:17
See my later post for a better description of the battery
 
that's badass. I wonder if it would hold up for my cl350?
Title: Re: 78 kz400 cafe build
Post by: Jonny on Apr 06, 2011, 23:51:40
mmm might be some thing i look into, going to be doing a kick start on my bike but think i want an electric start back up, ill look into it.
Title: Re: 78 kz400 cafe build
Post by: Beard on Apr 07, 2011, 01:01:18
My new battery came today. It will be going inside my seat. Its a 12v 6.0 amp hour. 

i have the same battery got it about a year ago.. like 24bucks shipped right... now im hoping to start my bike tomorrow or friday.. shake down run on sunday.. hoping the battery works out... kick only bike ofcourse
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Apr 07, 2011, 01:16:49
Yup, let me know how it works for you.
 
i have the same battery got it about a year ago.. like 24bucks shipped right... now im hoping to start my bike tomorrow or friday.. shake down run on sunday.. hoping the battery works out... kick only bike ofcourse
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Apr 09, 2011, 19:40:56
Made some progress today. I made a new rear hoop, mounted my battery, Made a new cluster mount to tidy up the front end and started the rear splash gaurd. I also took some random pictures while messing around with my wifes camera.
(http://i1080.photobucket.com/albums/j336/captain_neto/nice006.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/nice010.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/nice009.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/nice008.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/nice007.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/nice005.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/nice004.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/nice003.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/nice002.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/nice001.jpg)
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Apr 09, 2011, 19:58:01
one more
Title: Re: 78 kz400 cafe build
Post by: valvesprung on Apr 09, 2011, 21:04:18
Looks amazing man...after a nice weekend of riding my KZ...I really need some rearsets :)
Title: Re: 78 kz400 cafe build
Post by: jeffreyhardy on Apr 09, 2011, 22:51:45
great work on the rear fender and battery box man.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Apr 11, 2011, 01:09:59
I felt like doing some polishing so I did the ignition and part of the light switch housing. The lock cyl wasnt bad but the switch housing was a pain in the butt. Oh well I think it looks much better now. (http://i1080.photobucket.com/albums/j336/captain_neto/polish002.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/polish001.jpg)
Title: Re: 78 kz400 cafe build
Post by: AWDimprezal on Apr 14, 2011, 16:34:08
Very cool!
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Apr 14, 2011, 19:39:24
I finished the light switch now i'm stripping the start/kill switch. My plan is to machine new buttons out of brass and polish them. Thats the plan we will see.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Apr 14, 2011, 21:33:55
So I take it your a subi guy? My other ride is an 06 wrx.
Very cool!
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Apr 18, 2011, 21:07:30
I ordered a bunch of parts over the weekend. My taillight/turn, header wrap, pod filters, gaskets etc. I would like to put new rings in it while its apart, but as you kz guys know std. rings are hard to come by. My frame is ready to paint but now I cant decide what color to paint it. I need to figure out a paint scheme in order to continue this project. I was thinking about black for the frame, but I would like it to be a little more exciting. If I am going to paint the frame a color other than black then I need to figure out the color for the rest of the bike. A few ideas would be a gun metal and burgundy combo or maybe gunmetal & metalic blue. I also really like the blue and cream color on the coors can. I am open to other suggestions. I am really struggling with this so any input would be appreciated.
Title: Re: 78 kz400 cafe build
Post by: Erskine on Apr 18, 2011, 21:19:24
Gun metal and metallic blue would work.
Title: Re: 78 kz400 cafe build
Post by: Syke on Apr 18, 2011, 21:26:37
Any color combination, I'd advise against going with a light color on the frame.  Little matter of showing dirt too easily and it just doesn't work all that well.  If you've got any doubts, just look at a '71 BSA.  That dove grey frame color was one final nail in the coffin of that marque.

Burgundy and a dark blue?  The blue for the frame (keep it just light enough that it's definitely blue, not something you'd mistake for black on the first glance), burgundy for tank, fenders, etc.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Apr 18, 2011, 22:12:29
Yeah I want to keep the frame dark. I guess what I said was confusing. Gunmetal frame with burgundy tank and tail and maybe a gunmetal stripe down the tank/tail.
 
 
Any color combination, I'd advise against going with a light color on the frame.  Little matter of showing dirt too easily and it just doesn't work all that well.  If you've got any doubts, just look at a '71 BSA.  That dove grey frame color was one final nail in the coffin of that marque.

Burgundy and a dark blue?  The blue for the frame (keep it just light enough that it's definitely blue, not something you'd mistake for black on the first glance), burgundy for tank, fenders, etc.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Apr 18, 2011, 22:16:11
That would look cool! They need a program to put colors on a bike to preview them.
 
Yeah I want to keep the frame dark. I guess what I said was confusing. Gunmetal frame with burgundy tank and tail and maybe a gunmetal stripe down the tank/tail.
Title: Re: 78 kz400 cafe build
Post by: valvesprung on Apr 18, 2011, 23:21:31
Oh man, I dig the idea of the Coors can. Dark metallic blue frame, cream tins, gold pinstriping or cafe stripe! Maybe gold on the fork lowers?
Title: Re: 78 kz400 cafe build
Post by: biker_reject on Apr 19, 2011, 01:35:37
Any color combination, I'd advise against going with a light color on the frame.  Little matter of showing dirt too easily and it just doesn't work all that well.  If you've got any doubts, just look at a '71 BSA.  That dove grey frame color was one final nail in the coffin of that marque.

Burgundy and a dark blue?  The blue for the frame (keep it just light enough that it's definitely blue, not something you'd mistake for black on the first glance), burgundy for tank, fenders, etc.

Really, now.
Title: Re: 78 kz400 cafe build
Post by: grizwold on Apr 19, 2011, 04:45:32
do you happen to know what mufflers are on that Kawi?
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Apr 19, 2011, 21:32:48
My exhaust came in the mail today. Dime city was really cool about getting me a new muffler. The first one had a big dent in it from shipping. They were super quick, and helpful A+. I also got some engine paint and I picked up some valve lapping compound. Once my gaskets get here I will start tearing down the power plant. Sean at Roc City Cafe just put my SS clip on bars in the mail. He was also very nice to deal with. I needed my bars a little longer than the ones they normally make. He just sent me an E-mail and said he finished them and, they are on their way. The UPS guy will be getting to know my house quite well in the next few days.
Title: Re: 78 kz400 cafe build
Post by: MotorbikeBruno on Apr 20, 2011, 10:15:46
So are you painting the can?  (sorry if you said you were or were not going to earlier in the thread)  Wondering how it will "stick" to the chrome...
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Apr 20, 2011, 17:26:38
No, I will be leaving the can chome. I'm wrapping the headers in black.
 
So are you painting the can?  (sorry if you said you were or were not going to earlier in the thread)  Wondering how it will "stick" to the chrome...
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Apr 20, 2011, 17:27:14
The paint is for the engine.
 
No, I will be leaving the can chome. I'm wrapping the headers in black.
Title: Re: 78 kz400 cafe build
Post by: MotorbikeBruno on Apr 20, 2011, 17:29:54
Cool. You scared me  :o   haha.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Apr 20, 2011, 18:36:43
I wouldnt want to cover up that nice new chrome!  ;D  Especially after waiting for the undamaged one to get here.
 
 
 
Cool. You scared me  :o   haha.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Apr 20, 2011, 22:28:33
More goodies came in the mail today!!! New points, SS bolt kit and my new SS bars
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Apr 22, 2011, 00:57:00
I polished my master cylinder tonight. Its still needs a little work, but it looks much better than it did. I think I have arthritis in my fingers now. ;D  It was a major pain.
Title: Re: 78 kz400 cafe build
Post by: MotorbikeBruno on Apr 22, 2011, 18:17:13
That master looks great man. Keep it up.  I'm living vicariously through you because I can't work on mine right now...or should I say I need to get some of my friends bikes outta my space so I can work on mine!
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Apr 23, 2011, 09:33:30
I st(http://i1080.photobucket.com/albums/j336/captain_neto/lights010.jpg)arted mocking up my tail/turn lights. I also mounted my clip ons. I took a few pictures along the way. (http://i1080.photobucket.com/albums/j336/captain_neto/lights009.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/lights008.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/lights007.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/lights006.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/lights005.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/lights004.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/lights003.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/lights002.jpg)
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Apr 23, 2011, 10:46:01
I picked up this book now I can start my tear down (if my gaskets ever get here) I can put it back together. My son was helping me but he started reading his fovorite magazine and fell asleep.
Title: Re: 78 kz400 cafe build
Post by: CBdublin on Apr 23, 2011, 11:43:16
haha he's got the right ideas already... half naked chicks, motorcycles, and something to hold while taking a nap. nice.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Apr 24, 2011, 01:04:29
I tore down my rear wheel and polished the hub I painted the inside with VHT wrinkle paint. I am polishing the spokes and nipples in a brass tumbler (Thanks Epic Retry) This is an expirament. They have been in there about an hour and so far they look great. If it works it sure will beat doing them by hand, one at a time. I also have the top tree sitting in paint stripper waiting to be polished. (http://i1080.photobucket.com/albums/j336/captain_neto/hubahuba001.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/hubahuba002.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/hubahuba003.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/hubahuba004.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/hubahuba005.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/hubahuba006.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/hubahuba007.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/hubahuba008.jpg)
Title: Re: 78 kz400 cafe build
Post by: valvesprung on Apr 24, 2011, 01:55:50
Where'd you snag the tumbler? Seems like a great way to do that and the spokes on my new project will desperately need it...
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Apr 24, 2011, 02:29:07
My dad and I use it for realoading amunition. Most sprorting goods stores will be able to order them. Blue Press or Natchez would be another good place to look.
 
 
Where'd you snag the tumbler? Seems like a great way to do that and the spokes on my new project will desperately need it...
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Apr 25, 2011, 02:18:23
Got the rear all laced up and ready for rubber. The nipples and spokes turned out great after a few hours in the tumbler.(http://i1080.photobucket.com/albums/j336/captain_neto/lace001.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/lace002.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/lace003.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/lace004.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/lace005.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/lace006.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/lace007.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/lace008.jpg)
Title: Re: 78 kz400 cafe build
Post by: Epic retry on Apr 25, 2011, 20:42:04
I really like the way your wheel turned out ! that tumbler came in handy
Title: Re: 78 kz400 cafe build
Post by: Epic retry on Apr 25, 2011, 20:43:30
like the shag carpet also
Title: Re: 78 kz400 cafe build
Post by: valvesprung on Apr 25, 2011, 21:01:34
Yeah that carpet is amazing mate...truly awesome :)
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Apr 25, 2011, 22:34:32
The best part is...the walls match! Behold my man cave.
 
Yeah that carpet is amazing mate...truly awesome :)
Title: Re: 78 kz400 cafe build
Post by: Syke on Apr 25, 2011, 22:48:00
But, but, but . . . . . . . the shelves are empty!!!!!!!!!  Oh, the humanity . . . . . . . .
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Apr 25, 2011, 22:50:45
I guess we're getting a little off topic, so.....................This came in the mail today via Canadian post. (http://i1080.photobucket.com/albums/j336/captain_neto/gasket001.jpg)
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Apr 25, 2011, 22:52:00
If they were full I would never get my bike done. :o
 
But, but, but . . . . . . . the shelves are empty!!!!!!!!!  Oh, the humanity . . . . . . . .
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Apr 25, 2011, 23:12:49
Attempting to true the rear (http://i1080.photobucket.com/albums/j336/captain_neto/001.jpg)
Title: Re: 78 kz400 cafe build
Post by: FingerBanger on Apr 26, 2011, 01:34:21
I have more liquor than that in my car!
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Apr 26, 2011, 22:40:48
What do you think of these colors red frame metalic silver tank and hump, maybe a red+white stripe on the tank. This was my insparation.
Title: Re: 78 kz400 cafe build
Post by: valvesprung on Apr 27, 2011, 01:06:19
Red frames are tough to pull off, but the KZ has a nice frame
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Apr 28, 2011, 22:10:01
I bought my paint now I just need to figure out what goes where. This is just a quick sketch of a possible color scheme.
Title: Re: 78 kz400 cafe build
Post by: valvesprung on Apr 28, 2011, 23:40:36
I LOVE it man, very cool, very classy...
Title: Re: 78 kz400 cafe build
Post by: Syke on Apr 29, 2011, 00:07:08
That red frame reminds me of a Moto Guzzi cafe bike, late 70's or early 80's.  Can't think of the model, but it looks damned good.
Title: Re: 78 kz400 cafe build
Post by: stik70 on Apr 29, 2011, 00:27:26
Thats going to be a great looking motorcycle for sure. Keep up the awesome work!
Kev
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Apr 29, 2011, 00:54:50
Thanks for all the words of encouragement. I cant wait to start laying some paint. I would like to prime and paint all my parts at the same time so...i'm working to get all my body work done. I'm now at the stage of my build where I keep thinking, "man these little bikes sure do have a lot of parts." and "where did I put that.
Title: Re: 78 kz400 cafe build (New Shocks)
Post by: MILLENNIUM FALCON on Apr 30, 2011, 00:08:13
These little guys came in the mail today! I have finals this week and then I should FINALLY have some time to work on the bike.
(http://i1080.photobucket.com/albums/j336/captain_neto/shocks003.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/shocks002.jpg)
Title: Re: 78 kz400 cafe build
Post by: valvesprung on Apr 30, 2011, 01:15:52
So sick. I'm thinking about using those on my upcoming 400 tracker project and I'd love to hear how you like them when your on the road. What length did you go with?
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Apr 30, 2011, 01:27:11
I went with the 320mm. They are a little shorter than stock, but it looks like the bottom eye can be screwed out for adjustment.
Title: Re: 78 kz400 cafe build Primed to prime!
Post by: MILLENNIUM FALCON on May 02, 2011, 21:55:14
I got all the tabs ground of and worked a little more at fixing dents. I bet I ran the grinding wheel/flap disc for at least an hour. (not the most fun part of this build. It was very tedious but I think i will be glad I did it in the long run. I have off work tomorrow and would like to get the paint flying, but I don't see it getting done. (http://i1080.photobucket.com/albums/j336/captain_neto/frame005.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/frame004.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/frame003.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/frame002.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/frame001.jpg)
Title: Re: 78 kz400 cafe build
Post by: devon on May 02, 2011, 22:08:53
lookin good  8)
Title: Re: 78 kz400 cafe build
Post by: Syke on May 03, 2011, 00:00:09
At this point TAKE YOUR TIME!!!!!  So what if the bike's on the road 2-4 weeks later than planned?  You'll find that it's worth it.  And if you cut corners at this point, you're going to hate yourself everytime you pull the bike out into the sunlight.

What's your plans on baking the paint?
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on May 03, 2011, 00:45:28
I use a downdraft booth that can bake, but I usually don't bother. I have used the same base/clear on my own cars without baking it and have had great results. Do you bake your paint?
Title: Re: 78 kz400 cafe build
Post by: sbruton on May 03, 2011, 23:33:25
Hey man,

I've been watching your build for some time now... You're going all out on this!  It looks great. 
Looking forward to seeing your paint!
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on May 04, 2011, 01:05:42
Thanks, I cant wait to see it too. I enjoy building but I'm ready to see the end.

Hey man,

I've been watching your build for some time now... You're going all out on this!  It looks great. 
Looking forward to seeing your paint!
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on May 04, 2011, 01:12:02
My tires and tubes are here. (Avon AM26) I also got primer on today. I noticed a few spots that need fixed. I will probably start masking and applying color on Thursday. I can't wait to see how it turns out. ;D (http://i1080.photobucket.com/albums/j336/captain_neto/prime001.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/prime002.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/prime003.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/prime004.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/prime010.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/prime011.jpg)
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on May 04, 2011, 20:43:45
I messed around with some ideas. I was thinking.....the tank will be metallic silver. the knee dents will be white, and the blue tape will be a red stripe to match the frame. the other idea was the more pointy design but the same color scheme. What do you think.(http://i1080.photobucket.com/albums/j336/captain_neto/idea001.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/idea002.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/idea003.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/idea004.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/idea005.jpg)
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on May 04, 2011, 21:14:15
my vote is for this one.
Title: Re: 78 kz400 cafe build
Post by: valvesprung on May 04, 2011, 21:17:22
I like the second tank design, but think the first seat design is better and they'll work well together still. That being said, I still really like the first design as a whole too.

Can't wait to see this thing sparkling man!
Title: Re: 78 kz400 cafe build
Post by: Syke on May 04, 2011, 21:32:15
The pointy doesn't really work on the tailpiece.  Otherwise, mix and match at your leisure, it should look really good.

Re: Baking.  My method is to paint in the early spring, hang the parts in the attic until after labor day, then assemble.  Seems to let the paint harden very nicely.  Of course, it puts me on a strict schedule regarding painting.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on May 05, 2011, 22:16:22
Well I finally started painting. the seat and tank are done, the frame need 2 more coats of clear. I think it turned out great! Now I can start putting her back together.(http://i1080.photobucket.com/albums/j336/captain_neto/paint001.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/paint006.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/paint011.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/paint002.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/paint007.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/paint003.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/paint008.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/paint004.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/paint009.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/paint005.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/paint010.jpg)
Title: Re: 78 kz400 cafe build
Post by: jeffreyhardy on May 05, 2011, 22:43:51
What kind of paint are you using for the frame and tank? Nice work man. It's going to be a very classy paint scheme.
Title: Re: 78 kz400 cafe build
Post by: valvesprung on May 05, 2011, 23:15:33
Just kicked this up to a whole new level...so awesome man!
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on May 05, 2011, 23:27:06
Its PPG base/clear. For the silver color I just took the color code of off my Subaru WRX(Crystal Grey) I just really liked that color, the other colors are "mack white/ Gov. Red.

What kind of paint are you using for the frame and tank? Nice work man. It's going to be a very classy paint scheme.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on May 05, 2011, 23:29:38
Thanks I'm glad you like it.  The pictures are make the frame look really bright, but it is the same color as the stripe on the tank and seat. I hope to have a roller soon.
Just kicked this up to a whole new level...so awesome man!
Title: Re: 78 kz400 cafe build
Post by: wfo guy on May 05, 2011, 23:33:04
Good progress, man. Hope you don't scratch it during assembly.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on May 06, 2011, 00:01:31
Yeah me too. I plan on being very careful and using lots of padding. At least its only a 400.
Good progress, man. Hope you don't scratch it during assembly.
Title: Re: 78 kz400 cafe build
Post by: Epic retry on May 06, 2011, 15:51:00
 that looks fantastic !!!! gotta love those colors . Cant wait to see it together
Title: Re: 78 kz400 cafe build
Post by: JustinLonghorn on May 06, 2011, 15:55:02
The paint looks great, man.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on May 06, 2011, 17:39:29
thanks!
The paint looks great, man.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on May 07, 2011, 02:14:49
I got the new swing arm bearings in tonight. I also installed the swing arm and shocks. I will have more pictures tomorrow.(http://i1080.photobucket.com/albums/j336/captain_neto/001-1.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/002-1.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/003-1.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/004.jpg)
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on May 07, 2011, 02:22:42
one more picture for tonight.(http://i1080.photobucket.com/albums/j336/captain_neto/007.jpg)
Title: Re: 78 kz400 cafe build
Post by: reelinfeele on May 07, 2011, 09:32:51
what and where on the rear shocks.?? are those the $160 ebays?
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on May 07, 2011, 10:02:40
No, They are $75.00 ebay shocks. They seem surprisingly well made.
what and where on the rear shocks.?? are those the $160 ebays?
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on May 07, 2011, 10:51:21
I mounted the splash guard and rearsets. I set the tank and tail on it for a picture.(http://i1080.photobucket.com/albums/j336/captain_neto/006.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/008.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/008.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/009.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/010.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/011.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/012.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/013.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/014.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/015.jpg) 
Title: Re: 78 kz400 cafe build
Post by: RustyOlive on May 07, 2011, 11:32:50
just starting to read your thread from the beginning.. I cheated and jumped to the end to see the pic's lol.. bike is coming along nicely.
Title: Re: 78 kz400 cafe build
Post by: TheChild on May 07, 2011, 11:43:18
Amazing.  I love the color choices. 
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on May 07, 2011, 12:31:25
Thanks! it was kind of a last minute idea but I really like how it turned out.
Amazing.  I love the color choices.
Title: Re: 78 kz400 cafe build Speed holes
Post by: MILLENNIUM FALCON on May 08, 2011, 00:18:41
I drilled some speed holes in the rear hub. I should have the rear wheel mounted tomorrow! Then I will be moving onto the front end.(http://i1080.photobucket.com/albums/j336/captain_neto/speedholes001.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/speedholes002.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/speedholes003.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/speedholes004.jpg)
Title: Re: 78 kz400 cafe build
Post by: valvesprung on May 08, 2011, 00:34:32
Nice work man
Title: Re: 78 kz400 cafe build
Post by: CrescentSon on May 08, 2011, 01:30:00
The bike is looking outrageous. On that hub I'd profile the holes, and jump up one size on the outer holes just to clean it up, and add some visual depth respectively. On the whole, this is one clean ass build so far brother. Keep it up.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on May 08, 2011, 11:04:22
Thanks! I went with the smaller holes to miss the webbing on the back side of the hub. I don't think it would weaken it too much but I'd rather be safe than sorry. 
The bike is looking outrageous. On that hub I'd profile the holes, and jump up one size on the outer holes just to clean it up, and add some visual depth respectively. On the whole, this is one clean ass build so far brother. Keep it up.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on May 08, 2011, 22:35:59
I was planning on getting the rear wheel mounted and starting on the forks tonight but.........................I don't think its happening. Another day. ???
Title: Re: 78 kz400 cafe build
Post by: Syke on May 08, 2011, 23:19:42
Don't worry about it.  You're not on a schedule, this doesn't have to get done by tomorrow, and we're not even close to summer yet.  You've got at least 4-1/2 to 5-1/2 months riding season ahead of you (I'm an old Johnstown boy, I know).  Besides, if you rush you'll; a. Possibly mess something up that will disgust you later, and, b. Get so obsessed on finishing the bike that it'll kill a lot of the enjoyment of building it.

Take a break.  Go get laid.

And, if it makes you feel any better, my Bonnie's been blocking up my shop for six weeks now.  On a carburetor rebuild.  Two stinking carburetors.   :P
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on May 10, 2011, 21:25:50
I took a day off. today I got the rear wheel on and installed the tree/neck. I should get the forks polished soon.(http://i1080.photobucket.com/albums/j336/captain_neto/rear003.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/rear004.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/rear002.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/rear001.jpg)
Title: Re: 78 kz400 cafe build
Post by: biker_reject on May 11, 2011, 11:42:30
Looks awesome.  Looks like you've done everything right! 
Title: Re: 78 kz400 cafe build
Post by: treitz on May 11, 2011, 14:55:56
Wow this is coming along nicely! School and work have been kicking my arse lately. After this week maybe I'll have time to get caught up on here.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on May 11, 2011, 18:39:34
Thanks guys! Yeah tell me about it, I had finals this week. Now i'm back to "just" working full time so I should have alot more time to work on the bike. I got the forks/clip-ons/headlight ears on last night I will post some picture later tonight.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on May 11, 2011, 20:11:09
As promised here are some pictures of my progress.(http://i1080.photobucket.com/albums/j336/captain_neto/002-2.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/003-2.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/004-1.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/005-1.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/006-1.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/007-1.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/008-1.jpg)
Title: Re: 78 kz400 cafe build
Post by: Sonreir on May 11, 2011, 20:22:28
Lookin' good!
Title: Re: 78 kz400 cafe build
Post by: valvesprung on May 11, 2011, 20:24:27
Where'd you get the headlight ears? All the ones I've found im that style only go down to 35mm forks :(
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on May 11, 2011, 21:18:25
I got it from dime city. It says its only for 35mm forks but it comes with bushings that work. Its a pain but you can cut them down and they work fine.
Where'd you get the headlight ears? All the ones I've found im that style only go down to 35mm forks :(
Title: Re: 78 kz400 cafe build
Post by: platkeyboy on May 13, 2011, 09:48:09
Looking awesome.  You know, at the rate the bike-of-the-month nominations are going (1 so far), you can have the KZ done and give Ringo's CB some competition.  Haha.  I actually found this thread because went looking for a bike that could give him a run for his money, just for kicks.  I would say you're going in the right direction.  I am a bit jealous.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on May 13, 2011, 13:14:59
Thank you! I feel Honored that anyone would even compair my bike to Ringo's. :)
Looking awesome.  You know, at the rate the bike-of-the-month nominations are going (1 so far), you can have the KZ done and give Ringo's CB some competition.  Haha.  I actually found this thread because went looking for a bike that could give him a run for his money, just for kicks.  I would say you're going in the right direction.  I am a bit jealous.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on May 13, 2011, 18:43:10
Sadly I don't think I will have it finished in time.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on May 14, 2011, 00:14:26
I finished truing the front wheel. I got the tire mounted and slipped it in the forks to see what it looked like. I also polished the fuel cap remounted it.(http://i1080.photobucket.com/albums/j336/captain_neto/fwheel003.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/fwheel004.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/fwheel005.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/fwheel006.jpg)
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on May 14, 2011, 20:51:15
I'm going to drill my rotor tonight. I'm not sure if I want to drill a few big holes in a wave, or a ton of little holes in a tighter wave. Any input??
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on May 15, 2011, 00:29:40
Just finished drilling my rotor. I'm painting it then the front wheel can get installed for good!(http://i1080.photobucket.com/albums/j336/captain_neto/001-2.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/002-3.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/003-3.jpg)
Title: Re: 78 kz400 cafe build
Post by: valvesprung on May 15, 2011, 00:41:31
Perfect!
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on May 15, 2011, 00:57:19
Thanks! Drilling rotors is very time consuming and boring but its totally worth it!
Perfect!
Title: Re: 78 kz400 cafe build
Post by: PatDoody on May 15, 2011, 12:01:02
I love your bike! the progress is great.

Can I ask to see what drill bits you are using that make the little bevel on the hole? and where to get them. And how long do they last drilling hardened steel like that? I have been wanting to drill some lightening holes in some of my parts as well. Also any tips on laying out the holes so they wind up being symmetrical? thanks so much keep up the awesome work.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on May 15, 2011, 12:31:06
Sure Its an 80 degree countersinking bit. You can get them at most tool stores. I ordered this one on-line. Mcmaster carr has them.  The metal used on the rotor doesn't even phase these things. I have literally chamfered a thousand holes with that drill. The key is using the right cutting speed lots of lube and patience. As far as a patter I don't use one. Here is the method I use. My mill, indexing table and my handy angular spacing chart. Its so nice once you get setup and decide how many hole you want for every 360 degrees you just look at the chart and start drilling.



 
I love your bike! the progress is great.

Can I ask to see what drill bits you are using that make the little bevel on the hole? and where to get them. And how long do they last drilling hardened steel like that? I have been wanting to drill some lightening holes in some of my parts as well. Also any tips on laying out the holes so they wind up being symmetrical? thanks so much keep up the awesome work.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on May 15, 2011, 12:32:59
Here are some pictures of the other stuff 8) (http://i1080.photobucket.com/albums/j336/captain_neto/drill001.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/drill002.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/drill003.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/drill004.jpg)
Title: Re: 78 kz400 cafe build
Post by: PatDoody on May 15, 2011, 13:12:25
great stuff! I think I might actually have one of those bits in my dads old tool box and never realized what it was for. I wasnt sure if you had an all in one bit that drilled and countersunk similar to the wood bits available.

I been wanting to get a small mill for some time now. I have a large powerful drill press, I might just find a rotary indexing table for it for now.

Okay so on your chart there it looks like you drilled 18 holes so you would be drilling a hole at 20* 40* 60* etc? I think is how I am reading that.

Thanks for the reply I love the fabrication end of building bikes/cars usually even more than the end result.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on May 15, 2011, 13:38:06
Yup, 18 is what I used. 18 and 36 are the easiest because they fall on either 10 or 20 degrees. So you don't really even need the chart. The only tricky part is laying out the offset and spacing of the hole for the wave pattern. You don't want to get to the last hole and have it land half on and half off your rotor. If that happens you will kick yourself.
Title: Re: 78 kz400 cafe build
Post by: PatDoody on May 15, 2011, 14:01:28
hahaha ohh man I never thought of that! I would prob lay out a few test patterns with a sharpie first. Measure 16 times drill once. haha.
Title: Re: 78 kz400 cafe build
Post by: Slice on May 16, 2011, 16:53:54
Looks good!
Im not normally a KZ guy, but I like it so far!
-Slice
Title: Re: 78 kz400 cafe build ROLLER!!!!!
Post by: MILLENNIUM FALCON on May 17, 2011, 01:10:06
She is a roller as of tonight! I got my freshly drilled rotor on and front wheel mounted. I took some pictures of it resting on the kickstand. I will be moving from the basement to the garage for the final stage of this build. I also ordered my speedometer (sort of) tonight. Forward thrust will be measured via airspeed. I am working on a pitot tube for the airspeed indicator. (http://i1080.photobucket.com/albums/j336/captain_neto/roller001.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/roller002.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/roller003.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/roller004.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/speedeo.jpg)
Title: Re: 78 kz400 cafe build
Post by: valvesprung on May 17, 2011, 01:17:25
Looks truly spectacular man...one of the best red frame cafe builds I've seen, usually they just seem forced. This my friend, this looks fantastic...

Can't wait for completion and to here that exhaust!
Title: Re: 78 kz400 cafe build
Post by: platkeyboy on May 17, 2011, 12:18:48
Not that it would matter much to me if it was my bike, but it's hard to believe that an airspeed indicator measures low speeds accurately enough.  I mean, if you are riding in a 35mph speed zone, heading into 15-25mph winds, what would the gauge read, and would you alter your speed accordingly?  I would also think that riding behind a tractor-trailer in that vacuum (yes, I know that you have to get too close to it, but you get desperate in inclement weather sometimes) would throw off the gauge.  In our ridiculous modern age, 5mph can be the difference between a having a fun ride, and getting a $150 ticket.  Having said all of that, I have ridden (and driven) by tach alone in/on a few different vehicles, which can't be 100% accurate either, so I'm a hypocrite, haha.  These are just ponderings.  I think it's a pretty cool idea, and I hope it works out for you.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on May 17, 2011, 21:51:42
This gauge was made for an ultra-lite and is known for great slow speed accuracy, so It should be fairly close. Heck, the stock speedo was way off when compaired to my gps so I'm not to worried. If i'm drafting a tractor trailer than I'll just cross my fingers that he gets the ticket.  ;D This bike is not going to be my daily rider either. I just thought it would be cool and different than the "tach only" setups I have seen. I 'll let you know how it works.

Not that it would matter much to me if it was my bike, but it's hard to believe that an airspeed indicator measures low speeds accurately enough.  I mean, if you are riding in a 35mph speed zone, heading into 15-25mph winds, what would the gauge read, and would you alter your speed accordingly?  I would also think that riding behind a tractor-trailer in that vacuum (yes, I know that you have to get too close to it, but you get desperate in inclement weather sometimes) would throw off the gauge.  In our ridiculous modern age, 5mph can be the difference between a having a fun ride, and getting a $150 ticket.  Having said all of that, I have ridden (and driven) by tach alone in/on a few different vehicles, which can't be 100% accurate either, so I'm a hypocrite, haha.  These are just ponderings.  I think it's a pretty cool idea, and I hope it works out for you.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on May 20, 2011, 00:11:54
This came in the mail today! I got a trail lech tach/hour meter to count revs. I will use the airspeed gauge for mph and a red Flashing LED for oil pressure warning and a green Led for a nutral light. I am still working on my design/layout for the dash. I want to keep it tight and light. (http://i1080.photobucket.com/albums/j336/captain_neto/ars001.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/ars002.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/ars003.jpg)

Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on May 20, 2011, 00:12:40
I thinking about where to put it.(http://i1080.photobucket.com/albums/j336/captain_neto/ars004.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/ars005.jpg)
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on May 20, 2011, 12:15:29
I'm thinking about relocating my ignition to clean up the font end, but I hate to lose the neck lock and I don't really know where to put it.
Title: Re: 78 kz400 cafe build
Post by: platkeyboy on May 20, 2011, 12:52:04
I used to believe in neck locks, until I realized how easy they are to break.  Check this out: Dude stealing my motorcycle PART 1 (http://www.youtube.com/watch?v=bMVtKYBt5Q0#)

As far as the relocation is concerned, there are a few different options.  You honestly could hide a small toggle and push button somewhere (that only you know about) and nix the stock cylinder entirely.  I have had a few things stolen over the years, and I've learned that the best security is to park in highly public areas, and to always have it stored inside overnight. 

If you're thinking "Well I would have to at LEAST use a KEY," I would say that if someone wants to steal your motorcycle, they'll find a way to steal it...when it is left unwatched (by you or the public).  A keyed ignition and neck lock don't do a lot of good if you park it in an area where two guys can pick it up and set it in the back of a truck without anyone noticing.  Sorry to be such a downer, but people are evil sometimes.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on May 20, 2011, 14:35:07
Yeah people suck! Good point though. Is there much to wiring a toggle switch in place of a key lock. This bike is will be kick only.
Title: Re: 78 kz400 cafe build
Post by: platkeyboy on May 20, 2011, 16:16:29
No, it really shouldn't be complex.  I don't know if there are any exceptional issues with the ignition setup on your bike, but you could basically find the wire going from the key cylinder to the ignition, put that on one side of the switch, and simply run a 12V wire straight from your fusebox (or if you're not running one, use a fuse-able link), and connect it to the other side of the switch. 

If you want the lights on the same switch as the ignition, make sure to buy a switch that can handle a higher amperage,

OR you can use a tiny inconspicuous switch and use a relay instead.  This would be the "better safe than sorry" route, because it relieves the switch of the duty of carrying all of the amperage that your components will be using.  Just buy a standard 5-pole relay at the local parts store.  In this case, you would have a thin 12V wire feeding your tiny toggle switch, and the other side of the switch would feed pole "86" of the relay whenever you flip it.  Pole "85" would be grounded to the chassis or the negative battery terminal, pole "30" would be a thicker 12V supply from the battery (this one should be fused to handle both the ignition and lights), pole "87" will feed your lights AND ignition, and pole "87A" will be left unused. 

I know I have the relay part right, but if anyone has any other direction they would go with the whole thing, feel free to critique my ideas.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on May 21, 2011, 00:23:45
Thanks for all the info. I think I will be going that route. It shouldn't be a big deal. It will eliminate a lot of unused wires too. I might be asking you some more questions once I start my wiring.
No, it really shouldn't be complex.  I don't know if there are any exceptional issues with the ignition setup on your bike, but you could basically find the wire going from the key cylinder to the ignition, put that on one side of the switch, and simply run a 12V wire straight from your fusebox (or if you're not running one, use a fuse-able link), and connect it to the other side of the switch. 

If you want the lights on the same switch as the ignition, make sure to buy a switch that can handle a higher amperage,

OR you can use a tiny inconspicuous switch and use a relay instead.  This would be the "better safe than sorry" route, because it relieves the switch of the duty of carrying all of the amperage that your components will be using.  Just buy a standard 5-pole relay at the local parts store.  In this case, you would have a thin 12V wire feeding your tiny toggle switch, and the other side of the switch would feed pole "86" of the relay whenever you flip it.  Pole "85" would be grounded to the chassis or the negative battery terminal, pole "30" would be a thicker 12V supply from the battery (this one should be fused to handle both the ignition and lights), pole "87" will feed your lights AND ignition, and pole "87A" will be left unused. 

I know I have the relay part right, but if anyone has any other direction they would go with the whole thing, feel free to critique my ideas.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on May 25, 2011, 02:04:24
Tonight I finally started to work on my engine. I don't think it needs anything major. It just needs a few oil leaks fixed and some paint and polish. I cleaned it and started to disassemble things. So far everything looks clean and new. I hope to get her back together and in the frame asap. I also got my seat ready for leather. I had to notch out and epoxy some SS nut for the mounting bolt before the padding goes on.(http://i1080.photobucket.com/albums/j336/captain_neto/motor003.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/motor007.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/motor006.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/motor004.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/motor005.jpg)
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on May 25, 2011, 18:41:30
I will be pulling the head tonight (with pictures) after reasembly I plan on using vht cast aluminum paint for the block, vht wrinkle for the cylinder and polishing the valve cover and side covers. I am working on a fiberglass seat pan tonight as well.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on May 26, 2011, 01:17:31
I just pulled the head and everything looks good! I'm working on the head now. I also got the 1st layer of my seat pan done. (http://i1080.photobucket.com/albums/j336/captain_neto/002-4.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/003-4.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/004-2.jpg)
Title: Re: 78 kz400 cafe build
Post by: jeffreyhardy on May 26, 2011, 16:22:19
looks great for the age! what are your plans as far as cleaning up the internals? wire brush/wheel the valves and pistons? I ask because I am pulling the head on my bike next week.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on May 26, 2011, 18:38:11
Thats my current issue. I def. wouldnt use a wire wheel on the valves are seats. It would scratch the mating surfaces. I will prob. let them soak in some cleaner than take a tooth brush to em' They really aren't bad. I will post some pics later today. I will be lapping the valves tonight.
Title: Re: 78 kz400 cafe build
Post by: sovern on May 26, 2011, 23:13:59
Such an inspiration.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on May 28, 2011, 21:58:57
I painted my block last night. It turned out realllllly good. I was pleased. I just need to finish the valves and head. I cant wait to get this thing in the frame. (http://i1080.photobucket.com/albums/j336/captain_neto/enginepaint003.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/enginepaint005.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/enginepaint006.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/enginepaint004.jpg)
Title: Re: 78 kz400 cafe build
Post by: stript.714 o/c on May 28, 2011, 22:10:06
Dude loving the craftmanship i own the same year bike. I like how you used a sk8 helmet as a seat bumb great idea.
 just dropping a message so i can keep track of the build cheers.
Title: Re: 78 kz400 cafe build
Post by: valvesprung on May 28, 2011, 23:20:04
Loving it man
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on May 28, 2011, 23:22:21
Thanks! I looked everywhere for somthing to give me the shape I wanted for a seat.  Then I saw that helmet. $7 at target. It was a pink princess helmet. I built that seat about a year before I started my bike build so the seat sat on a shelf in my basement. Every single person that saw it had questions. "what is that?" "What is a cafe Racer?" "That hat has a big ass brim?" I finaly put it where people couldnt see it.
Dude loving the craftmanship i own the same year bike. I like how you used a sk8 helmet as a seat bumb great idea.
 just dropping a message so i can keep track of the build cheers.
Title: Re: 78 kz400 cafe build
Post by: reelinfeele on May 28, 2011, 23:44:20
Looking good bro. I saw your post on the 26mm carbs. My past experience with different carb sizes is not good. You will end up trying to jet for less air and have no power. not worth the hassle, IMO. 32 to 26 is almost 20% drop in airflow. It will run, but your buddy on the ouch will be blowing your doors off.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on May 29, 2011, 00:06:39
Thanks for the heads up. That
s why I asked. What carbs are you running? What do most people run on Kz400's for performance?
Looking good bro. I saw your post on the 26mm carbs. My past experience with different carb sizes is not good. You will end up trying to jet for less air and have no power. not worth the hassle, IMO. 32 to 26 is almost 20% drop in airflow. It will run, but your buddy on the ouch will be blowing your doors off.
Title: Re: 78 kz400 cafe build
Post by: reelinfeele on May 29, 2011, 10:46:17
i am running the stock 32cv's. with pods. 80 primary's and 105 mains. stock exhaust, runs great. mine is a 77 with rubber dia. should be the same as yours. my kz1000 taught me the different carb size lesson. I went from 29's to 34's. took a year to get it close and it still ran better with the stock carbs.
Title: Re: 78 kz400 cafe build
Post by: stript.714 o/c on May 29, 2011, 18:35:33
Thanks! I looked everywhere for somthing to give me the shape I wanted for a seat.  Then I saw that helmet. $7 at target. It was a pink princess helmet. I built that seat about a year before I started my bike build so the seat sat on a shelf in my basement. Every single person that saw it had questions. "what is that?" "What is a cafe Racer?" "That hat has a big ass brim?" I finaly put it where people couldnt see it.
HAAAAH that Is  to funny. i get that all the time what is a cafe racer . Great idea on the bump i see all types of crafty things being used for the bump butt i think this is my favorite yet! Yo your bike build should be called the pink princess :P  hah J/K.
 Later Dude
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on May 30, 2011, 18:10:44
Engine cases before polishing(http://i1080.photobucket.com/albums/j336/captain_neto/covers002.jpg)After (http://i1080.photobucket.com/albums/j336/captain_neto/covers003.jpg)
Title: Re: 78 kz400 cafe build
Post by: valvesprung on May 30, 2011, 18:26:26
Those look amazing!
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on May 31, 2011, 02:33:30
I am to tired to take any pictures......but the head has been cleaned and prepped for paint. I opened up the ports a little and smoothed out all the ridges and castings inside the ports. The valves have been cleaned and lapped. vinegar works if you have patience!
Title: Re: 78 kz400 cafe build
Post by: jeffreyhardy on May 31, 2011, 04:09:36
the engine cases look freaking beautiful. what kind of polish? Yeah vinegar and a toothbrush I heard rocks
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on May 31, 2011, 08:15:16
Thanks, Yeah Its really good stuff. Its called METAL GLO Its comes in a tube and looks more like wax than polishing compound. It works really fast. Once I sanded them I only had about an hour at the wheel.
the engine cases look freaking beautiful. what kind of polish? Yeah vinegar and a toothbrush I heard rocks
Title: Re: 78 kz400 cafe build
Post by: stript.714 o/c on May 31, 2011, 18:52:02
Those cleaned up good . Looks like they where already in good shape, they cleaned up nice!!
Title: Re: 78 kz400 cafe build
Post by: Ian Oberholtzer on Jun 01, 2011, 02:53:06
amazing indeed


so pretty pleased with the wrinkle finish? thinking about doing it on my bottom end, jugs and head
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Jun 01, 2011, 22:14:58
I got the valves back in and finished the paint. I will be bolting her back on tonight.(http://i1080.photobucket.com/albums/j336/captain_neto/004-3.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/003-5.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/002-5.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/001-3.jpg)
Title: Re: 78 kz400 cafe build
Post by: Tim on Jun 01, 2011, 23:12:20
That engine is gonna be a jewel.
Title: Re: 78 kz400 cafe build
Post by: valvesprung on Jun 02, 2011, 01:14:31
So sexy...
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Jun 02, 2011, 01:47:04
Thanks for all the compliments! I got the head on and side covers. I just hope it still looks like this once its in the frame.  :P   Here is my latest progress..(http://i1080.photobucket.com/albums/j336/captain_neto/001-4.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/002-6.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/003-6.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/004-4.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/005-2.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/006-2.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/007-2.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/008-2.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/009-1.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/011-1.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/010-1.jpg)
Title: Re: 78 kz400 cafe build
Post by: valvesprung on Jun 02, 2011, 01:58:04
Nail...head...contact...
Title: Re: 78 kz400 cafe build
Post by: bikeboy on Jun 02, 2011, 08:20:42
now that's a purty lookin' motor.

nice work.

ian
Title: Re: 78 kz400 cafe build
Post by: Tim on Jun 02, 2011, 10:34:25
You should try and get a set of pics from exactly the same spot of each component being added on to make a film of it being pieced together.
Title: Re: 78 kz400 cafe build
Post by: JustinLonghorn on Jun 02, 2011, 10:35:48
That sure is a pretty motor. Yep.
Title: Re: 78 kz400 cafe build
Post by: reelinfeele on Jun 02, 2011, 11:01:10
looking good man. are you polishing the rocker covers?
Title: Re: 78 kz400 cafe build
Post by: FingerBanger on Jun 02, 2011, 11:36:12
I read back through the thread, but couldn't find what kind of paint you were using on the engine (particularly the head)
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Jun 02, 2011, 20:38:13
I used vht wrinkle plus. (advanced auto) The silver is the vht header paint.
I read back through the thread, but couldn't find what kind of paint you were using on the engine (particularly the head)
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Jun 02, 2011, 20:39:36
I was going to but didnt have the patience. It will be the same as the head. I did polish the tappet covers and the top breather/vent.
looking good man. are you polishing the rocker covers?
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Jun 02, 2011, 20:40:56
That would be really cool. I had never thought of that. I wish I had thought of that in the beginning. That would make a sweet video.
You should try and get a set of pics from exactly the same spot of each component being added on to make a film of it being pieced together.
Title: Re: 78 kz400 cafe build
Post by: stript.714 o/c on Jun 02, 2011, 21:10:21
Dude stop showing off that engine!!!! lol. I like that engine stand where do i get one?
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Jun 02, 2011, 23:53:41
Haha......I got the stand at grizzly tools for $39 I used some 3/8 threaded rod for the mounts. I really made it nice to work on.
Dude stop showing off that engine!!!! lol. I like that engine stand where do i get one?
Title: Re: 78 kz400 cafe build
Post by: Caf'd Out on Jun 02, 2011, 23:54:17
purdy clean my friend. you got some patience for sure. Is that a custom engine stand? excuse my newbness but i have never seen one like that for bike motors..
Title: Re: 78 kz400 cafe build
Post by: Caf'd Out on Jun 02, 2011, 23:57:19
ok so i got linked to page 25 and didnt realize my question was answered on page 27. Carry on.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Jun 02, 2011, 23:59:14
Thanks! Its a car engine stand but it works great for bikes. quote author=Caf'd Out link=topic=22980.msg281722#msg281722 date=1307069839]
ok so i got linked to page 25 and didnt realize my question was answered on page 27. Carry on.
Title: Re: 78 kz400 cafe build
Post by: stript.714 o/c on Jun 03, 2011, 19:14:11
Haha......I got the stand at grizzly tools for $39 I used some 3/8 threaded rod for the mounts. I really made it nice to work on.
i like the stand. i am always using my garage table , but it ends up pretty grimey .
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Jun 07, 2011, 00:08:25
Tonight was a big moment for me! The kz finaly made the long journey from its home in the basement to its new home in the garage. A good friend of mine came over and we very carefully reinstalled the power plant. That pipe insulation was the best $6 bucks I ever spent. Not a single scratch on the frame or the engine. I was sweating and praying the entire time but, it went off without a hitch. (http://i1080.photobucket.com/albums/j336/captain_neto/motorin001.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/motorin002.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/motorin003.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/motorin004.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/motorin005.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/motorin006.jpg)
Title: Re: 78 kz400 cafe build
Post by: valvesprung on Jun 07, 2011, 00:13:35
Looks so damned perfect man...the silver/polished looks amazing, just enough black too...well done!
Title: Re: 78 kz400 cafe build
Post by: Syke on Jun 07, 2011, 00:18:16
Ghod, I hope that bike never sees wet roads.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Jun 07, 2011, 00:43:51
thanks guys. Yeah I threw up a little in my mouth at the thought of ever getting stuck on a freshly oil/chipped road!!!!!!!!!!!!!!!! :-[ :'( :'( haha
Title: Re: 78 kz400 cafe build
Post by: biker_reject on Jun 07, 2011, 01:07:59
Diggin' the rearset mounts - and the shocks are tits!
Title: Re: 78 kz400 cafe build
Post by: vincent84 on Jun 07, 2011, 09:10:06
well done bro... really nice job..
Title: Re: 78 kz400 cafe build
Post by: Tim on Jun 07, 2011, 16:39:37
Once you start riding it, you'll obsess less :)  I ride the crap out of my once-mirror polished aluminum clad XS and am happy it's getting some well earned scrapes and bumps.

(http://i13.photobucket.com/albums/a275/CB550F/DO%20THE%20TON%20Alabama%202010/KillBoy1.jpg)
Title: Re: 78 kz400 cafe build
Post by: valvesprung on Jun 07, 2011, 17:15:57
Yup, he's right, I washed the bike every chance I got the first summer, but now I realize how much more bad ass it looks with a bit of grime and usage :)
Title: Re: 78 kz400 cafe build
Post by: stript.714 o/c on Jun 08, 2011, 00:02:07
Nice work.  funny how we micro stress on the smallest things that people wont ever see on our bikes. You will give up a bit once you realize there is nothing you can do when the earths elements take in to place. All you will care about is just riding the hell out of that 400 ;D
Title: Re: 78 kz400 cafe build
Post by: Syke on Jun 08, 2011, 00:15:01
Welcome to why I'm so damned happy that my Bonnie is 42 years old, completely original, put me in the hospital once, and shabby as hell.  But it runs.  And I know every inch of it.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Jun 10, 2011, 00:46:23
I got the rocker cover on tonight. I set the tank and seat on for a few pics. Its coming together..............(http://i1080.photobucket.com/albums/j336/captain_neto/enginetank013.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/enginetank014.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/enginetank015.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/enginetank017.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/enginetank018.jpg)
Title: Re: 78 kz400 cafe build
Post by: valvesprung on Jun 10, 2011, 00:59:17
good gawd man...stop teasing me!
Title: Re: 78 kz400 cafe build
Post by: CBdublin on Jun 10, 2011, 15:42:47
man she's looking sweet
Title: Re: 78 kz400 cafe build
Post by: dean owens on Jun 10, 2011, 21:37:32
very nice.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Jun 11, 2011, 03:51:20
Thank you! I hope to have it wired up and running soon. I will post videos when I do.
very nice.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Jun 12, 2011, 10:38:47
Rolled her outside for some pics. Exhaust about 80 percent done.(http://i1080.photobucket.com/albums/j336/captain_neto/outside001.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/outside003.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/outside004.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/outside008.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/outside005.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/outside006.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/outside007-1.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/outside007-1.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/outside007.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/outside002.jpg)
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Jun 12, 2011, 10:42:05
one more................... (http://i1080.photobucket.com/albums/j336/captain_neto/outside006.jpg)
Title: Re: 78 kz400 cafe build
Post by: valvesprung on Jun 12, 2011, 14:03:39
It just keeps getting better and better...
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Jun 12, 2011, 17:04:25
Thanks man! I just keep getting more and more excited to fire her up. I really hate wiring, so im not looking forward to the next step.
It just keeps getting better and better...
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Jun 15, 2011, 23:46:00
My two goals for tonight are to get the carbs torn apart and see how they look. Clean and replace as necessary. I also will be milling out my sexy new carb holders to fit the 400 head. (Thanks valvesprung) I will try to post progress pics in an hour or two. (http://i1080.photobucket.com/albums/j336/captain_neto/001-5.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/002-7.jpg)
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Jun 16, 2011, 01:45:12
Ok I got the boots on and carbs are cleaned I polished the bowls. Everything looked really clean inside, but i'm sure I will need to re-jet. Any of you kz400 guy know a good starting point for pods and 2-1 exhaust? Thanks(http://i1080.photobucket.com/albums/j336/captain_neto/004-5.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/003-7.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/002-8.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/001-6.jpg)
Title: Re: 78 kz400 cafe build
Post by: Slice on Jun 16, 2011, 09:43:34
Wow... she is looking REALLY nice.
-Slice
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Jun 19, 2011, 23:46:35
Thanks man! Hey Have you messed around with jetting much on your KZ? I am looking for a good source for jets or Jet kits. Thanks.
It just keeps getting better and better...
Title: Re: 78 kz400 cafe build
Post by: valvesprung on Jun 19, 2011, 23:52:40
I have not. One of the shops early on did a bit, but it was before I knew what to ask. Right now it runs ok with the airbox and peashooters, a little lean, but not bad
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Jun 23, 2011, 22:02:11
My seat is now finished and mounted. I am really happy with how it turned out.(http://i1080.photobucket.com/albums/j336/captain_neto/seaton001.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/seaton002.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/seaton003.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/seaton004.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/seaton005.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/seaton006.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/seaton007.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/seaton008.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/seaton008.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/seaton009.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/seaton010.jpg)
Title: Re: 78 kz400 cafe build
Post by: reelinfeele on Jun 23, 2011, 22:08:22
Badass dude. Bikes coming together pretty sweet. Im dying to know how those rear shocks works.
Title: Re: 78 kz400 cafe build
Post by: valvesprung on Jun 24, 2011, 02:12:51
Brown with diamond quilts...where have I seen that...


...Love it dude :) I love the material man, much better than mine and closer to what I was looking for.
Title: Re: 78 kz400 cafe build
Post by: valvesprung on Jun 24, 2011, 02:14:13
Brown with diamond quilts...where have I seen that...


...Love it dude :) I love the material man, much better than mine and closer to what I was looking for.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Jun 24, 2011, 02:24:54
Thanks, I guess we both have good taste  ;D
Title: Re: 78 kz400 cafe build
Post by: stript.714 o/c on Jun 24, 2011, 06:56:29
Dude she looks amazing. Are you going to ride her ,or are you just going to take pictures of her all day?,lol lets go
Title: Re: 78 kz400 cafe build
Post by: platkeyboy on Jun 24, 2011, 10:48:14
That seat may be a matter of personal taste, and personally I like it -- a lot.
Title: Re: 78 kz400 cafe build
Post by: treitz on Jun 24, 2011, 12:04:52
Looks REALLY, really good. Love the seat.

As far as jetting goes... I don't have pods, or 2-1 exhaust, but I can tell you what I know and you can take it for what it's worth.

First off, jets for this bike are expensive compared to most. I bought mine at jetsrus.com. The good news is that they have them all. The bad news is they have a $7 flat rate shipping. Which I guess is fine if you order enough jets. Mains were $5 each + shipping.

Anyways... I have K&N Style intakes and 2-2 exhaust and only went up 1 size all the way around. 72 on the main and 92 or whatever on the secondary. With POD's and 2-1, my initial instinct would be to go 2 or 3 sizes up from stock and see how it runs.

I could be wrong, but that is what I would try.
Title: Re: 78 kz400 cafe build
Post by: CBdublin on Jun 24, 2011, 18:18:21
i dont usually go for the thicker padded seats but i really DIG this one. its hard to stay unique in this ever growing niche so i like where you went with it. looks great
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Jun 24, 2011, 20:16:27
Thanks for all the kind words and tips. Trust me I cant wait to stop taking pics and start riding!
Title: Re: 78 kz400 cafe build
Post by: stript.714 o/c on Jun 25, 2011, 17:00:50
just bustin ur balls i am really digin ur bike ;D
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Jun 28, 2011, 23:43:29
I am at the beach so the bike is resting until I get back. Yes, I am procrastinating.......I hate wiring!
Title: Re: 78 kz400 cafe build
Post by: Syke on Jun 29, 2011, 00:10:41
Damn!  I was in Johnstown (my old home town) for Thunder in the Valley over the weekend.  Was able to catch all the text messages keeping me in touch with what was going on, but the phone wasn't good enough to handle the pictures.  That bike is bloody gorgeous!  Don't worry about the wiring.  Keep is simple.  Start with what you need to get it to run and charge the battery.  Then get the lights to work.  Anything more  . . . . . . . don't bother.  It won't make the bike go any faster or handle any better.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Jun 29, 2011, 00:40:22
  Thanks I am happy with how it's turning out. I am debating on reusing the stock harness or making a new one. I want to keep it a neat and simple as possible.
Damn!  I was in Johnstown (my old home town) for Thunder in the Valley over the weekend.  Was able to catch all the text messages keeping me in touch with what was going on, but the phone wasn't good enough to handle the pictures.  That bike is bloody gorgeous!  Don't worry about the wiring.  Keep is simple.  Start with what you need to get it to run and charge the battery.  Then get the lights to work.  Anything more  . . . . . . . don't bother.  It won't make the bike go any faster or handle any better.
Title: Re: 78 kz400 cafe build
Post by: platkeyboy on Jun 29, 2011, 10:03:28
You might regret doing all of that other work, but sticking with the old, bulky, and ugly stock harness.  Of course, this is coming from someone who wouldn't mind doing that type of thing, as 12V wiring is kind of my thing.  If you go with stock, I'm sure you'll be trimming a bunch of excess off, and when you do, double check and/or replace the stock connectors using the right connectors and tools.  Have fun.
Title: Re: 78 kz400 cafe build
Post by: treitz on Jun 29, 2011, 10:33:38
I used stock, and wish I had gone simple. Mine went back together just fine, but a guy named Bryan who is building one in the brat style section simplified it and it looks pretty easy.

Here is his thread... http://www.dotheton.com/forum/index.php?topic=21678.0 (http://www.dotheton.com/forum/index.php?topic=21678.0)

Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Jun 29, 2011, 11:09:15
Thanks for the advice I will check it out!
Title: Re: 78 kz400 cafe build
Post by: lucas2696 on Jun 29, 2011, 14:21:30
Looks nice dude, can't wait to see how those shocks work out, I'm thinking about getting some of those off the Bay for my Honda!
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Jul 07, 2011, 01:36:03
Its been awhile but I finally got some ambition and did a little work on the bike. I wired up the switch housings and mounted them. I need to paint my headlight bucket and run some wires. (http://i1080.photobucket.com/albums/j336/captain_neto/controls006.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/controls007.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/controls008.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/controls009.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/controls010.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/controls011.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/controls012.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/controls013.jpg)
Title: Re: 78 kz400 cafe build
Post by: lucas2696 on Jul 07, 2011, 01:47:23
That thing is gorgeous! I really like the drilled levers, looks very cool. 8)


 PS: What was your first impression of those shocks?
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Jul 07, 2011, 02:02:36
Thanks! I cant tell you how they perform yet, but they seem surprisingly well made. I am looking forward to blasting into a bumpy corner with them. They are much stiffer than the stockers



That thing is gorgeous! I really like the drilled levers, looks very cool. 8)


 PS: What was your first impression of those shocks?
Title: Re: 78 kz400 cafe build
Post by: lucas2696 on Jul 07, 2011, 02:14:45
Good to hear! Once I get my 450 going again, that'll be one of the first things I do.
Title: Re: 78 kz400 cafe build
Post by: Rattlecan on Jul 07, 2011, 09:56:38
Wow what a great build keep up the good work.  I'll be following it from now on.
Title: Re: 78 kz400 cafe build
Post by: Walkin_Stick on Jul 07, 2011, 12:00:05
This thing is turning out amazing. I'm glad to see so many KZ's getting built. I'd like to know how those shocks work out too. They look great.
Title: Re: 78 kz400 cafe build
Post by: biker_reject on Jul 07, 2011, 14:15:22
Beautiful work, my friend.
Title: Re: 78 kz400 cafe build
Post by: stript.714 o/c on Jul 07, 2011, 23:45:19
 Yo mock up your head light so we can get an idea of how it will look , for your color skeem
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Jul 08, 2011, 01:32:32
I will bolt it up tomorrow and take a few picks.....
Yo mock up your head light so we can get an idea of how it will look , for your color skeem
Title: Re: 78 kz400 cafe build
Post by: CBdublin on Jul 08, 2011, 12:27:00
i voted for white and red... from the side profile i think it would look cool and uniform with the white sections of the bike. perhaps with the actual rim of the light being red and the housing being white. i know chrome is king but i always like the pop of the rim being painted. or even a red strip along the rim of the white housing and the light being the same color as the tank.... SO MANY OPTIONS!
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Jul 08, 2011, 23:08:59

I thought about painting the headlight ring, but I am worried about the durability. I think it would look awesome.  I will have some headlight mockup pictures up soon. I need to find my headlight bolts.  :-\ In the meantime here are some pictures of my mounted air speed gauge. It still needs plumbed up, but at least its bolted on.(http://i1080.photobucket.com/albums/j336/captain_neto/painting009.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/painting010.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/painting011.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/painting012.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/painting013.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/painting014.jpg)
Title: Re: 78 kz400 cafe build
Post by: 1976cb356 on Jul 09, 2011, 00:32:25
Sweet guage looks like an aircraft guage, Idk if it is or if thats what it is suppose to look like, but its sweet
Title: Re: 78 kz400 cafe build
Post by: ROCKO on Jul 09, 2011, 08:34:19
is it normal to get a hard on looking at cool shit like this  :o
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Jul 09, 2011, 09:03:36
Thanks, yeah it is a functional airspeed gauge. It was made for small aircraft like ultralites so it is made to accurately read slower speeds.

Sweet guage looks like an aircraft guage, Idk if it is or if thats what it is suppose to look like, but its sweet
Title: Re: 78 kz400 cafe build
Post by: stript.714 o/c on Jul 09, 2011, 10:26:36
 Silver and chrome on the head light bucket. i still want to see the head light bucket mock up. No red your frame is alot of red already. I am liking the speedo tach it sits very flat and flush to the bikes dienamics . Tell us more about where u got this air plane speedo? i found a picture that looks similar to your bike it might give you an idea what you could do,I also put a link to a build my friend just finished . Your going to laugh at how similar your guys color lay outs are! cheers! Stript
http://kottmotorcycles.com/Kott_Motorcycles/Builds/Pages/CB-T500.html#1 (http://kottmotorcycles.com/Kott_Motorcycles/Builds/Pages/CB-T500.html#1)
Title: Re: 78 kz400 cafe build
Post by: BoneDaddy on Jul 09, 2011, 10:54:58
That is so effing cool.

Might I ask where you got the gauge and how it's wired?
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Jul 09, 2011, 14:15:43
Ok I got the headlight bolted up. I will most likely be lowering it a little. Let me know what you think.
 I got the gauge from a company called Aircraft Spruce. They specialize in small aircraft and DIY airplane builders. It actually measures the differential in air pressure between the static pressure and the pressure from the pitot tube to measure the motorcycles speed. It should be quite accurate unless you are riding directly into the wind. those bikes do look similar to mine. Is the Kott bike built by the same guy that was in the "Cafe Cowboy" video in DTT?(http://i1080.photobucket.com/albums/j336/captain_neto/mock004.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/mock003.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/mock002.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/mock001.jpg)
Title: Re: 78 kz400 cafe build
Post by: stript.714 o/c on Jul 09, 2011, 15:29:17
Yes thats him , sweet little vid aint it! i would go silver with the chrome lip . That gage is tech!
Title: Re: 78 kz400 cafe build
Post by: Walkin_Stick on Jul 09, 2011, 16:49:08
I agree with Stript. I think silver would blend right in. I just realized I hadn't said it yet but I love that seat.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Jul 11, 2011, 01:06:21
I finished the airspeed gauge tonight. It is all plumbed up and functional. I made a short walk around video.http://youtu.be/5wGv4nyi8mA (http://youtu.be/5wGv4nyi8mA)
Title: Re: 78 kz400 cafe build
Post by: stript.714 o/c on Jul 11, 2011, 01:35:00
 Thanks for explaining how the air speedo works, i like that thing it should work once you are running the bike. How does it measure the air in psi ,mph, ?
Title: Re: 78 kz400 cafe build
Post by: Swapmeet Louie on Jul 11, 2011, 01:43:01
Satin Black
Title: Re: 78 kz400 cafe build
Post by: Reddy on Jul 11, 2011, 04:13:44
I hate your seat.  Actually I just do not like the color.  Everything else about your scoot I just love.  Really nice job.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Jul 12, 2011, 01:41:18
I apologize if the color of my seat offended you. :D   
I hate your seat.  Actually I just do not like the color.  Everything else about your scoot I just love.  Really nice job.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Jul 12, 2011, 01:43:25
I almost forgot I had a large hole the side of my engine. This should take care of the problem.(http://i1080.photobucket.com/albums/j336/captain_neto/starterplug002.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/starterplug001.jpg)
Title: Re: 78 kz400 cafe build
Post by: 1976cb356 on Jul 12, 2011, 02:18:28
did you buy that or make it? looks perfect
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Jul 12, 2011, 02:54:14
thanks! i made it. i used my starter as a pattern, chucked up some 2" and started making chips. it took me about an hour .

did you buy that or make it? looks perfect
Title: Re: 78 kz400 cafe build
Post by: stript.714 o/c on Jul 12, 2011, 05:08:20
So you going just kick start then. It is crazy how heavy the little straters can be
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Jul 12, 2011, 07:33:42
Yeah I am going as light and simple as possible. I bet between the battery and starter it will shave at least 10 pounds.
So you going just kick start then. It is crazy how heavy the little straters can be
Title: Re: 78 kz400 cafe build
Post by: treitz on Jul 12, 2011, 10:56:19
I apologize if the color of my seat offended you. :D   

Haha I love the color of the seat. Don't lists to that guy ;-)
Title: Re: 78 kz400 cafe build
Post by: treitz on Jul 12, 2011, 10:56:59
Listen*
Title: Re: 78 kz400 cafe build
Post by: biker_reject on Jul 12, 2011, 13:04:51
I hate how pretty your bike is...
Title: Re: 78 kz400 cafe build
Post by: stript.714 o/c on Jul 12, 2011, 15:19:07
Yeah hey what a terrible build!!!!!! :'(
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Jul 12, 2011, 19:10:54
Come on guys.......I have feelings.
Title: Re: 78 kz400 cafe build
Post by: kelvis on Jul 12, 2011, 21:58:36
I think your seat shows really nice attention to detail. It's small, quality items like that that make bikes like yours stand out from the other run-of-the-mill builds. Good stuff!
Title: Re: 78 kz400 cafe build
Post by: neeko1979 on Jul 12, 2011, 22:01:33
Nice ride bro...
Title: Re: 78 kz400 cafe build
Post by: 1976cb356 on Jul 12, 2011, 23:55:19
I dont know whats wrong with the seat, I think its sweet and the silver and white is original and classy. And I think your headlight bucket should be silver, but thats just me. Good looking bike!
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Jul 13, 2011, 00:35:12
Thanks for all the compliments guys. I am really leaning toward silver with a chrome ring for my headlight. I want to keep it simple. I was going to go with black for the seat but I really wanted to be different plus I really felt it gave my bike the more vintage custom feel.    I guess that's what great about building these old bikes for ourselves......we get to make them exactly how we want to.
Title: Re: 78 kz400 cafe build
Post by: hapakev on Jul 13, 2011, 00:52:02
I'm a little late, but that gauge is TITS!
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Jul 13, 2011, 02:05:19
I'm just busting on you. :) We are all entitled to our opinion. Thanks for checking out my build.
I hate your seat.  Actually I just do not like the color.  Everything else about your scoot I just love.  Really nice job.
Title: Re: 78 kz400 cafe build
Post by: Witeq on Jul 14, 2011, 17:52:10
This seat is shit but motorcycle is nice :D
Title: Re: 78 kz400 cafe build
Post by: lucas2696 on Jul 14, 2011, 17:58:26
Wow, what a nice first post.  >:(
Title: Re: 78 kz400 cafe build
Post by: 1976cb356 on Jul 14, 2011, 18:21:41
Wow, what a nice first post.  >:(
I think someone is jealous and made a profile to try and sabatoge his build thread.  ::)
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Jul 14, 2011, 18:52:11
You have such a way with words. A little turbo Lax might dislodge that stick/bug that is making you so grumpy.
 
 
This seat is shit but motorcycle is nice :D
Title: Re: 78 kz400 cafe build
Post by: stript.714 o/c on Jul 14, 2011, 19:51:53
What a troll. Guy pooped out of no where and just slays your hard work.




 So give us a run down on what is left for you to do?
 Also i have a kz 400  do you have any spare cylinder jugs,reusable valves,or a spare piston laying around?
Cheers
Title: Re: 78 kz400 cafe build
Post by: biker_reject on Jul 14, 2011, 19:58:30
I have one too ('74), but it's a project for down the road.  After following at this thread, I can't wait to get my hands on it.
Title: Re: 78 kz400 cafe build
Post by: stript.714 o/c on Jul 14, 2011, 20:44:37
I know right. 8)
Title: Re: 78 kz400 cafe build
Post by: neeko1979 on Jul 14, 2011, 21:28:24
I have one too ('74), but it's a project for down the road.  After following at this thread, I can't wait to get my hands on it.
i'm curious about the bike you use  as your avatar...it's pretty sweet...what is it
Title: Re: 78 kz400 cafe build
Post by: lucas2696 on Jul 14, 2011, 21:29:42
It's a Buell, XB9?
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Jul 14, 2011, 21:43:17
List of things to do:

1) Build wiring harness.
2) Install harness
3) Build and install rear turn signal bracket.
4) Paint Headlight bucket/tank emblems
5) Install Front brake caliper/rebuild master cylinder
6) Fab some sort of a front fender
7) get a new chain/sprocket
8) Fuel Lines
9) finish wrapping exhaust
10) A few other bits and pieces to install/hook up

As far as spare parts I dont have any engine parts. Wish I could help you out.


What a troll. Guy pooped out of no where and just slays your hard work.




 So give us a run down on what is left for you to do?
 Also i have a kz 400  do you have any spare cylinder jugs,reusable valves,or a spare piston laying around?
Cheers
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Jul 16, 2011, 01:03:50
Tonight I ordered my ss brake line and banjo fittings and a master cylinder rebuild kit. My banjo bolt pressure switch was delivered today as well. One step closer to completion. I hope to have time to work on things this weekend.
Title: Re: 78 kz400 cafe build
Post by: 1976cb356 on Jul 16, 2011, 02:32:49
Tonight I ordered my ss brake line and banjo fittings and a master cylinder rebuild kit. My banjo bolt pressure switch was delivered today as well. One step closer to completion. I hope to have time to work on things this weekend.
Thats funny, I worked on my brake switch today also.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Jul 17, 2011, 08:30:04
I went with silver and red on the headlight. Thanks for all the input (votes) guys, The number on the edge of the headlight bucket is my Grandfathers ship number. He was a machinist in the Navy. He was on Destroyer Escort DE343 in WWII. I wish he was here to see my bike. I used his machines and tools to build everything on this bike. I made the front fender from the stock fender. The emblem are off the stock KZ400 tank. As soon as the clear cures these parts will be going on the bike.  That is the last of sanding and painting for this project....YIPPPY!(http://i1080.photobucket.com/albums/j336/captain_neto/paintII001.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/paintII002.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/paintII004.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/paintII005.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/paintII003.jpg)this is a picture of DE-343(http://i1080.photobucket.com/albums/j336/captain_neto/343.jpg)
Title: Re: 78 kz400 cafe build
Post by: 1976cb356 on Jul 17, 2011, 14:55:09
Thats awesome ur grandfather would be proud. I like the pin striping, how do you do it? Is it vinyl? Looks perfect anyways.
Title: Re: 78 kz400 cafe build
Post by: stript.714 o/c on Jul 17, 2011, 16:24:23
Those bits really turned out great . I like the striping on the headlight bucket!
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Jul 17, 2011, 17:26:10
Thanks! It's real easy. I just paint red where ever I want the stripes to be, then I put down the vinyl 1/8 mask, paint the silver, pull off the tape then it's ready for clear.
Title: Re: 78 kz400 cafe build
Post by: reelinfeele on Jul 17, 2011, 17:45:16
This build is making me want to keep mine. Looking at a gs550 right now. Again, im dying to know how those shocks work for you.
I thinking this is a future BOTM.
Nice work dude.
Title: Re: 78 kz400 cafe build
Post by: 1976cb356 on Jul 17, 2011, 18:19:41
This build is making me want to keep mine. Looking at a gs550 right now. Again, im dying to know how those shocks work for you.
I thinking this is a future BOTM.
Nice work dude.
I agree with the BOTM.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Jul 18, 2011, 00:39:41
Thanks, I guess I need to get this thing finished....  I snapped a few pictures of the freshly painted bits. I didnt really have any time to work on the kz today. :( (http://i1080.photobucket.com/albums/j336/captain_neto/002-9.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/003-8.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/004-6.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/005-4.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/006-4.jpg)
Title: Re: 78 kz400 cafe build
Post by: lucas2696 on Jul 18, 2011, 00:41:18
I love the cut on the front of that fender! Good job!  8)
Title: Re: 78 kz400 cafe build
Post by: Epic retry on Jul 18, 2011, 09:37:32
I gotta tell you . Your bike exceeds anything I thought it would be. you have shone a lot of talent . The  DE343 is a real classey touch  . AND brown workes for me! H.E.H would love it keep up the good work
Title: Re: 78 kz400 cafe build
Post by: stript.714 o/c on Jul 18, 2011, 11:44:56
I guess I need to get this thing finished.... 
There you go keep crossing things off the list, Its the season,You dont want to wait till winter to ride that thing! Or do you? Did you rattle can that ?
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Jul 18, 2011, 13:40:31
Yeah I would like to be able ride it without tire chains and heated grips ::)
 
There you go keep crossing things off the list, Its the season,You dont want to wait till winter to ride that thing! Or do you? Did you rattle can that ?
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Jul 18, 2011, 13:41:29
The paint it a PPG base/clear automotive paint (no rattle)
Yeah I would like to be able ride it without tire chains and heated grips ::)
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Jul 18, 2011, 13:42:22
Thanks, I was trained by the best.
 
I gotta tell you . Your bike exceeds anything I thought it would be. you have shone a lot of talent . The  DE343 is a real classey touch  . AND brown workes for me! H.E.H would love it keep up the good work
Title: Re: 78 kz400 cafe build
Post by: valvesprung on Jul 18, 2011, 13:50:33
I'm still loving it man, very nice work as always. I think lowering that front fender 0.5-0.75" would really help...now that it's apinted :P
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Jul 18, 2011, 19:54:55
Yeah that would look good. It wouldnt be to hard. I still might do it. My main goal now is getting it running. I would worry about messing up the paint too.
I'm still loving it man, very nice work as always. I think lowering that front fender 0.5-0.75" would really help...now that it's apinted :P
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Jul 20, 2011, 00:11:01
Master cylinder rebuild came today. Fresh from Canada. New ss brake line and banjo fittings should be in by the end of the week.
Title: Re: 78 kz400 cafe build
Post by: stript.714 o/c on Jul 20, 2011, 00:15:03
Cool. why dont you just replace your master cylinder with a after market one?
 
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Jul 20, 2011, 02:17:58
I thought about it. The one I am using is off a cb350f. I like the old look. As long as it works I want to keep the "vintage" look. Also $20 for a rebuild is easy on my already drained budget.
Title: Re: 78 kz400 cafe build
Post by: stript.714 o/c on Jul 20, 2011, 11:43:01
Thats what i figured. i like the the little square ones they dont look as bulky. cant go wrong though$ 20 buckers .
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Jul 21, 2011, 23:21:56
I rebuilt my Master cylinder, mounted my caliper and installed new hose and fittings. One more thing off the list!!! 8) (http://i1080.photobucket.com/albums/j336/captain_neto/001-7.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/002-10.jpg)
Title: Re: 78 kz400 cafe build
Post by: MotorbikeBruno on Jul 22, 2011, 17:22:44
Is that caliper painted or is that sand blasted without anything on it?  I like it either way, just wondering.
Title: Re: 78 kz400 cafe build
Post by: stript.714 o/c on Jul 22, 2011, 18:24:46
Nice! lets go keep it pushing i want to see a video of it running already. :o
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Jul 22, 2011, 23:34:02
  It's vht ceramic paint. I wanted to polish it but didn't have the patience.
Is that caliper painted or is that sand blasted without anything on it?  I like it either way, just wondering.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Jul 22, 2011, 23:37:07
 I will be posting a video. I can't wait to hear it run. Vintage days are going to slow me down this weekend.
Nice! lets go keep it pushing i want to see a video of it running already. :o
Title: Re: 78 kz400 cafe build
Post by: reelinfeele on Jul 23, 2011, 00:13:02
Yes we need video.
Title: Re: 78 kz400 cafe build
Post by: stript.714 o/c on Jul 23, 2011, 05:57:15
Yeah hearing  it run is always the bizness

Title: Re: 78 kz400 cafe build
Post by: mcge8241 on Jul 24, 2011, 01:49:27
Love the build, lots of inspiration for my own KZ400.  Just curious, but do you know how much the bike weighs now?   
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Jul 24, 2011, 09:07:43
Thanks. Its funny you should ask about weight, I was just thinking about weighing it. I will post some numbers when I do. It should be a good bit lighter than it was. I have a few more things to add so she will get a little chunkier but not much.     
Love the build, lots of inspiration for my own KZ400.  Just curious, but do you know how much the bike weighs now?
Title: Re: 78 kz400 cafe build
Post by: mcge8241 on Jul 24, 2011, 09:30:32
Thanks. Its funny you should ask about weight, I was just thinking about weighing it. I will post some numbers when I do. It should be a good bit lighter than it was. I have a few more things to add so she will get a little chunkier but not much.   

Yes please do, I could NOT believe how heavy the bike was when I looked it up...386 lbs or around there.  Seems like there is a lot of weight to come off. 
Title: Re: 78 kz400 cafe build (LET THERE BE LIGHT)
Post by: MILLENNIUM FALCON on Jul 29, 2011, 01:38:49
I finally started the wiring. I decided to modify the stock harness because it was in good shape and I was using everything minus elect. start and the idiot lights. I may make a custom harness down the road, but for now I am eliminating whatever I dont need, and changing the length of leads that have been relocated. I charged up my battery for a test. I have headlight/tail light, and spark. I need to re-route and hide everything. Just for fun I adjusted the valves, sprayed some fuel in the holes and gave her a few kicks. I got a small backfire but that was it. More to come. (http://i1080.photobucket.com/albums/j336/captain_neto/power001.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/power002.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/power003.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/power004.jpg)
Title: Re: 78 kz400 cafe build
Post by: 1976cb356 on Jul 29, 2011, 01:50:36
That is coming along nice. I am exciting about getting my rolling chassis going. Thanks for the motoviation. ;D
Title: Re: 78 kz400 cafe build
Post by: mcge8241 on Jul 29, 2011, 09:50:26
Looking sharp.

Is that a westach gauge you are using for speed?  What sort of sensor does it use to read the speed...?
Title: Re: 78 kz400 cafe build
Post by: valvesprung on Jul 29, 2011, 11:18:47
Getting so close...
Title: Re: 78 kz400 cafe build
Post by: stript.714 o/c on Jul 29, 2011, 11:27:50
nice good to hear shes ALIVE
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Jul 29, 2011, 18:34:46
its a falcon airspeed gauge it uses a pitot tube to read airspeed.


Looking sharp.

Is that a westach gauge you are using for speed?  What sort of sensor does it use to read the speed...?
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Jul 30, 2011, 21:46:14
 The numbers in as she sits right now the ms weighs 286 pounds. It still needs a chain and headlight but nothing to heavy. I am pleased with the weight drop from nearly 400lbs
Love the build, lots of inspiration for my own KZ400.  Just curious, but do you know how much the bike weighs now?
Title: Re: 78 kz400 cafe build
Post by: stript.714 o/c on Jul 31, 2011, 00:01:24
not bad minus 120 . The starter was at least half that weight  ;D
Title: Re: 78 kz400 cafe build
Post by: mcge8241 on Jul 31, 2011, 11:15:01
Very cool idea with the airspeed gauge, I like that a lot!

And that's an AWESOME weight drop.  Gives me a real nice idea of where I will be headed...I'm doing a lot of the same weight reduction stuff and frame modifications that you are with one of my KZ400s.

I can't loose the starter tho...I picked up a 440cc engine for $60 yesterday, but it does not have a kick-start :(

Strong work, either way.  Love the build.  Wanna make me one of those seats???
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Jul 31, 2011, 14:34:35
I wouldnt mind making another one. there wasnt much to it.


Very cool idea with the airspeed gauge, I like that a lot!

And that's an AWESOME weight drop.  Gives me a real nice idea of where I will be headed...I'm doing a lot of the same weight reduction stuff and frame modifications that you are with one of my KZ400s.

I can't loose the starter tho...I picked up a 440cc engine for $60 yesterday, but it does not have a kick-start :(

Strong work, either way.  Love the build.  Wanna make me one of those seats???
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Aug 02, 2011, 01:38:54
I worked on the wiring some more tonight. Its pretty much done. I still need to decide if I am going with the stock ignition or just a switch. I did hook up my Oil pressure LED warning light. just a few more little things. My chain came today. I will get that on soon. My list is getting smaller. (http://i1080.photobucket.com/albums/j336/captain_neto/002-11.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/003-9.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/004-7.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/005-5.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/006-5.jpg)My little helper tonight. (http://i1080.photobucket.com/albums/j336/captain_neto/001-8.jpg)
Title: Re: 78 kz400 cafe build
Post by: JustinLonghorn on Aug 02, 2011, 08:50:09
That dash is a thing of beauty, sir.
 
Getting so close man.
Title: Re: 78 kz400 cafe build
Post by: MotorbikeBruno on Aug 04, 2011, 12:56:10
That dash is a thing of beauty, sir.
 
Getting so close man.

So EFFING True.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Aug 05, 2011, 00:06:51
Thanks guys. I'm glad you like it. It has been fun to daydream the way I want something to look and then make it happen. The wiring is finished I will try to get some photos of my switch mounting and new (mini) horn. The next step is getting her running. I a concerned that the timing is of or the cam gear is 180 off because I cant get anything more than a backfire out of her. Tonight I will be trying to diagnose the problem. I followed the manual very closely upon reassembly and everything went well, but I may be pulling the rocker cover off. Any suggestions???
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Aug 06, 2011, 12:54:59
You learn something new everyday....kz's use a wasted spark ignition so it cant be 180 off. So need to continue my diagnostics.
Title: Re: 78 kz400 cafe build
Post by: MotorbikeBruno on Aug 06, 2011, 13:37:10
Of by a "tooth" aka a link on the timing chain maybe?  I never opened up the engine on my KZ440 I used to have so I can't be of much help, but I was ONE frickin half-link off on my KZ650 and that made it hate me.  Hope you find it soon though.
Title: Re: 78 kz400 cafe build (Won't Start!!)
Post by: MILLENNIUM FALCON on Aug 06, 2011, 18:55:33
Well I had the timing chain and cam right. I took everything apart and found out I did it correctly. I was hoping to find somthing obvious. I put it all back together re-adjusted the valvesut fueled her up and still nothing. It back fires and pops. i got a small flame out the exhaust and carbs (not at the same time). I put new points on when I put the engine in so I thought they might be bad. I put the old points/condenser back on, and got the same results. I did check the compression and I had 147 on the left and 152 on the right. This is frustrating. any thoughts.(http://i1080.photobucket.com/albums/j336/captain_neto/time004.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/time003.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/time002.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/time001.jpg)
Title: Re: 78 kz400 cafe build
Post by: reelinfeele on Aug 06, 2011, 22:29:53
Points gap? Have someone there to advance and retard the timing while you kick it. Set the valves loose to make sure one is not hung up. Is the coil conected correctly, power and trigger not backwards? Battery good and fresh? Fuel??? I have done that, carbs were fresh but floats had stuck closed, kicked it for an hour. Crank goes backwards. Just throwing stuff out there. 
Title: Re: 78 kz400 cafe build
Post by: reelinfeele on Aug 06, 2011, 23:19:33
The notch on the camshaft should be straight up????????? At tdc.. Yours is different than mine but thats how mine should be. There not that much different.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Aug 06, 2011, 23:40:17
I just going off of the service manual and it says the arrow in the cam gear goes straight ahead and the notch in the cam goes straight back. It has a picture and everything but you never know. What year is your bike? I checked the point gap. The kz400.com showed the cam going back in the way I did it. Thanks for the help.

The notch on the camshaft should be straight up? ??? ??? ?? At tdc.. Yours is different than mine but thats how mine should be. There not that much different.
Title: Re: 78 kz400 cafe build
Post by: reelinfeele on Aug 07, 2011, 00:25:33
I have a D model, last of. Yours is a B. Sorry any mis info. Im about to put mine together tomorrow, so my mind is already thinking.
Good luck.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Aug 07, 2011, 09:00:34
I looked on kz400.com at the d model rebuild and the notch does go straight up. I'm surprised that they are that different. I hope to figure this problem out soon.
I have a D model, last of. Yours is a B. Sorry any mis info. Im about to put mine together tomorrow, so my mind is already thinking.
Good luck.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Aug 07, 2011, 15:58:04
FIXED!!!!!!!!!!!!!!! She is alive!! I knew it would be something stupid. I had a feeling it was a timing issue. So just sat in the garage watching the valves go up and down with a flashlight in the spark plug hole. Then i noticed the points were opening at bdc. Duh... you cant put the timing andvance plate in wrong because the shaft is keyed, but you can put the tube that cams the points open on backwards. I had to take it apart to clean/grease it and I must have put it together backwards. Oh well. She started up on the first kick upon reassembly. It sounds great! I will be posting a video this afternoon. Thanks for all the Help.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Aug 07, 2011, 17:40:46
I will post a better video when I get my other camera, but you get the idea. I also took a picture of my pitot tube cover.(http://i1080.photobucket.com/albums/j336/captain_neto/running002.jpg)http://youtu.be/gfqh3V8uAbo (http://youtu.be/gfqh3V8uAbo)
Title: Re: 78 kz400 cafe build (RUNNING VIDEO)
Post by: MILLENNIUM FALCON on Aug 07, 2011, 17:42:49
running!! 001 (http://www.youtube.com/watch?v=gfqh3V8uAbo#)
Title: Re: 78 kz400 cafe build
Post by: 1976cb356 on Aug 07, 2011, 17:47:29
Sweet! I love your exhaust, how it barely pokes out, sweet bike, nice job.
Title: Re: 78 kz400 cafe build
Post by: Tim on Aug 07, 2011, 18:06:43
For Youtube and other vids just paste the full URL into your post - the site will take care of the rest :)
Title: Re: 78 kz400 cafe build
Post by: wfo guy on Aug 07, 2011, 18:14:18
Congratulations!
Title: Re: 78 kz400 cafe build
Post by: reelinfeele on Aug 07, 2011, 18:42:35
Awesome!! Glad it was something simple. Sounds good. Almost got mine back together today. Should have measured the clutch springs earlier. Oh well, looks great man, good job. Now you gotta be dying to ride her. I want to know how those rear shocks work for you. Botm, next month.
Title: Re: 78 kz400 cafe build
Post by: neeko1979 on Aug 07, 2011, 18:54:07
is that a reverse cone megaphone muffler?
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Aug 07, 2011, 19:34:02
Thanks guys. I am really excited to hit the road. Its about 98% done. I will let you know how the shocks work out. (Neeko)The exhaust is a 17" reverse megaphone from dime city. (Reelin) I'm honored that anyone would think my bike is a contender for BOTM.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Aug 07, 2011, 19:34:37
Thanks man!
Sweet! I love your exhaust, how it barely pokes out, sweet bike, nice job.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Aug 09, 2011, 23:23:53
I put my chain on, hooked up the clutch and sprocket cover last night. I also bled the brakes. It moved about 4 feet under its own power. Whoo hoo. I am working on the rear brakes tonight. I am concerned however with two small bubbles that have formed on my tank. I think it is weeping fuel. I used a slide hammer to pop out some dents and I must not have sealed up the welds good enough. I need to figure out a way to seal it up or I will be stripping down the tank to repair it. I really dont want to do that. Any suggestions.  I also hid all my wiring and mounted my seat with a nice rubber seal.(http://i1080.photobucket.com/albums/j336/captain_neto/DSC_0001.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/DSC_0002.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/DSC_0003.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/DSC_0004.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/DSC_0005.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/DSC_0006.jpg)
Title: Re: 78 kz400 cafe build
Post by: 1976cb356 on Aug 09, 2011, 23:26:55
Love your rear sets, the rubber seal is pretty cool, Thats unfortunate that your paint bubbled. My dad had the same problem with a car ( bigger bubble tho) and he use a very small and sharp needle and popped it and it went down. Very hard to notice if that, Good Luck.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Aug 10, 2011, 00:21:54
Thanks! Yeah I dont think its a big deal. If I cant fix it, I have more paint/clear. Regardless I have off work thursday so...weather pending she will be hitting the road!
Title: Re: 78 kz400 cafe build
Post by: Syke on Aug 10, 2011, 00:31:14
Regarding the tank problem.  Get yourself the sealant that comes with the Kreem kit.  You can buy it separately, rather than buying the entire treatment.  It fixed a slight split on the weld on my Bonneville about ten years ago when the rear rubber mount went south.  Any motorcycle shop that deals with either Tucker Rocky or Parts Unlimited should be able to get it.  If you need, I can dig up the part numbers when I go to work tomorrow.

The sealant is like a thick vanilla milkshake.  Normally you put it in after the A treatment (essentially oxalic acid) and the B treatment (which neutralizes the acid), and the tank dries out.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Aug 10, 2011, 00:56:03
Thats sounds like what I need. If you have a part number that would be very helpful. Thanks.
Regarding the tank problem.  Get yourself the sealant that comes with the Kreem kit.  You can buy it separately, rather than buying the entire treatment.  It fixed a slight split on the weld on my Bonneville about ten years ago when the rear rubber mount went south.  Any motorcycle shop that deals with either Tucker Rocky or Parts Unlimited should be able to get it.  If you need, I can dig up the part numbers when I go to work tomorrow.

The sealant is like a thick vanilla milkshake.  Normally you put it in after the A treatment (essentially oxalic acid) and the B treatment (which neutralizes the acid), and the tank dries out.
Title: Re: 78 kz400 cafe build
Post by: teazer on Aug 10, 2011, 01:03:01
That's a KZ440 twin?  No way. 

Excellent transformation and nice attention to detail.
Title: Re: 78 kz400 cafe build
Post by: 1976cb356 on Aug 10, 2011, 01:08:02
I see that you haven't put the spring on your kickstand yet, when I did it I had todo some touch up and I needed the help of someone esle to put the bolt in while I pulled down on it. Hopefully there isn't a common sense way to put it on, because I would look pretty stupied. But this might seem like a dumb question and believe me I tried looking it up, but what is the purpose of putting a block of wood under the kickstand?
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Aug 10, 2011, 01:33:31
It uses two springs, one on the front and one on the back. The one on the back is on. I use a pair of needle nose to put it on. I you put the spring on with the stand in the "up" position there will be much less, or no tension on the spring which makes it much easier to put on. The block of wood was just to make the bike sit up to make it easier to works on, thats all.
I see that you haven't put the spring on your kickstand yet, when I did it I had todo some touch up and I needed the help of someone esle to put the bolt in while I pulled down on it. Hopefully there isn't a common sense way to put it on, because I would look pretty stupied. But this might seem like a dumb question and believe me I tried looking it up, but what is the purpose of putting a block of wood under the kickstand?
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Aug 10, 2011, 01:34:08
Thank you sir.
That's a KZ440 twin?  No way. 

Excellent transformation and nice attention to detail.
Title: Re: 78 kz400 cafe build
Post by: 1976cb356 on Aug 10, 2011, 01:41:48
Oh now I see it ahah, but i bet this thing will be sweet to ride, especially looking down at the cool guage.
Title: Re: 78 kz400 cafe build
Post by: joeyputt on Aug 10, 2011, 01:48:34
Brother you have done an absolutely beautiful job on this motorcycle! Very nice!
Title: Re: 78 kz400 cafe build
Post by: reelinfeele on Aug 10, 2011, 18:53:25
Red Kote, the best ever. I swear it would seal a battleship after a torpedo. its always something.
Title: Re: 78 kz400 cafe build
Post by: Erskine on Aug 10, 2011, 20:11:33
Looking pretty damn classy there my man :)
Title: Re: 78 kz400 cafe build
Post by: valvesprung on Aug 10, 2011, 20:37:02
Yeah...please don't use Kreem, I've seen so many tanks just destroyed by poor installs. POR-15 and Red Kote are MUCH better...
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Aug 10, 2011, 20:44:37
Thanks, GTK. I am debating on whether or not to drill my sprocket cover, any thoughts?
Title: Re: 78 kz400 cafe build
Post by: 1976cb356 on Aug 10, 2011, 21:05:24
You could do the brass screening, but idk if it would look good with the red?
Title: Re: 78 kz400 cafe build
Post by: reelinfeele on Aug 10, 2011, 21:16:50
When in doubt, drill it out....
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Aug 13, 2011, 00:51:49
I rode the kz for the first time in nearly 3 years. It was great. Everything worked and nothing fell off or exploded............yet ;) .
I only rode it a mile or 2 near my house. But it ran surprisingly well. If felt very light and fast with its new trim weight. It felt great to give her one kick, pull out of the garage and head down the road on my creation. I am working on a video. Stay tuned.
 
Title: Re: 78 kz400 cafe build
Post by: stript.714 o/c on Aug 13, 2011, 05:24:30
Good for you nothing beats that first ride  8)  Hard work payed off
Title: Re: 78 kz400 cafe build
Post by: catseye on Aug 13, 2011, 07:42:11
super job. WOW!!
(http://images.bimmerforums.com/smilies/buttrock.gif)
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Aug 13, 2011, 10:02:10
Jb weld seems to have fixed my tank issue (for now) Drilled sprocket cover. I tried to keep is simple. Bar end mirrors installed. (http://i1080.photobucket.com/albums/j336/captain_neto/102_5075.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/102_5076.jpg)
Title: 78 kz400 cafe build
Post by: neeko1979 on Aug 13, 2011, 12:46:50
Cosmetically this bike is awesome. I hope u can square away all the mechanical issues so you can ride and enjoy it.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Aug 13, 2011, 13:01:36
 Thanks! I rode it a little yesterday and everything felt good. I'm checking bolts and fluids then I'm hitting the road some more
Cosmetically this bike is awesome. I hope u can square away all the mechanical issues so you can ride and enjoy it.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Aug 13, 2011, 23:22:49
Now that I know everything works i decided to give her a tune up. I'm sure it needs jetted and a carb sync, I will get there. I gapped and installed new plugs. I checked point gap and cam chain tension. Then I got out the timing light, fired her up and checked/set the timing and checked the advance. Man she sure does sound nice and smooth now. Her is a picture of the plugs I took out. They look a little on the lean(hot) side. One more grey-ish, one more tan-ish. (in my opinion.) What do the pros think? Is my jetting way off? Does anyone know a good source for Kei-hin jets?(http://i1080.photobucket.com/albums/j336/captain_neto/102_5077.jpg)
Title: Re: 78 kz400 cafe build
Post by: pugeyed on Aug 14, 2011, 06:07:55
hi just read this all the way through, excellent build very impressed with you eye for detail, hope you get your jetting issue sorted, ever thought of making a clear airbox out of perspex? that way you still get to see the filters but it richens it up a bit.
im rebuilding a kz750 but have just bought another project.
dont want to blog your thread etc, by all means ask me to remove the link if you want.
here is the link
http://www.dotheton.com/forum/index.php?topic=28492.0 (http://www.dotheton.com/forum/index.php?topic=28492.0)
Good luck and all the best
Mark.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Aug 14, 2011, 07:50:11
Thanks, It seems to be running quite well. I just want to make sure its not running lean. it idles smooth and doesnt backfire or pop to bad.  I dont think I will have much trouble with jetting. This is the fun part now. I made my creation Now I get to perfect and fine tune it.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Aug 14, 2011, 07:53:28
That looks like its going to be a sweet bike. gotta love the big bores. Thanks for checking out my build
hi just read this all the way through, excellent build very impressed with you eye for detail, hope you get your jetting issue sorted, ever thought of making a clear airbox out of perspex? that way you still get to see the filters but it richens it up a bit.
im rebuilding a kz750 but have just bought another project.
dont want to blog your thread etc, by all means ask me to remove the link if you want.
here is the link
http://www.dotheton.com/forum/index.php?topic=28492.0 (http://www.dotheton.com/forum/index.php?topic=28492.0)
Good luck and all the best
Mark.
Title: Re: 78 kz400 cafe build
Post by: reelinfeele on Aug 14, 2011, 11:17:14
Pjmotorsports.com for jets. Im running 80 primary and 105 secomdary mains. I am stock exhaust with pods. It runs great. Their jets are cheap and the shipping is crazy fast. Cant wait for the video. Good job dude.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Aug 14, 2011, 23:41:02
I went to pjmotorsports and they only listed primaries for the kz400. Did you have trouble finding secondary jets?
Pjmotorsports.com for jets. Im running 80 primary and 105 secomdary mains. I am stock exhaust with pods. It runs great. Their jets are cheap and the shipping is crazy fast. Cant wait for the video. Good job dude.
Title: Re: 78 kz400 cafe build
Post by: reelinfeele on Aug 14, 2011, 23:56:48
Go to the keihin jets page and scroll throught the single jets. I had to measure mine for physical size, forget what it was. Once i figured out the size height and width of the jet it was easy. They are one of the "small round" jets. It wont say for bike specific. You have to search it. If you call he will just point you to model search, nice guy but not willing to give you wrong answer, which is cool if you ask me. They are the jet in front of needle main, engine side.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Aug 15, 2011, 00:23:44
Ok thanks. Its nice that they post all the dimensions. Yeah you can't blame them for not wanting to sell people the wrong jets.
Title: Re: 78 kz400 cafe build (SHORT RIDE VIDEO)
Post by: MILLENNIUM FALCON on Aug 15, 2011, 20:03:35
I will be making a "Good" video as soon as I get all the bugs worked out. I just thought you guys might like a little sneak peek and listen.
Tonight I will be tearing the carbs of and ordering jets.Movie (http://www.youtube.com/watch?v=jCy_a81nI1E#)
Title: Re: 78 kz400 cafe build
Post by: reelinfeele on Aug 15, 2011, 20:37:26
Sounds great! Got mine running today. Your pipe, made or bought?
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Aug 15, 2011, 20:53:56
Thanks! The Header I made (page 9,10) the can is from dime city.
Sounds great! Got mine running today. Your pipe, made or bought?
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Aug 16, 2011, 00:30:31
Jets are ordered.
Title: Re: 78 kz400 cafe build
Post by: valvesprung on Aug 16, 2011, 00:57:13
Well once you know they work, let me know what the specs are. I'm still a bit lean with my peashooters and stock air box...but they are jetted pretty lean from the get go.
Title: Re: 78 kz400 cafe build
Post by: biker_reject on Aug 16, 2011, 10:59:50
Arghhh!  Work computer no have sound!  Congrats on the completion of your build.  I totally love it.
Title: Re: 78 kz400 cafe build
Post by: mcge8241 on Aug 16, 2011, 13:23:03
http://i1080.photobucket.com/albums/j336/captain_neto/005-5.jpg (http://i1080.photobucket.com/albums/j336/captain_neto/005-5.jpg)

Have a question about your triple clamp...that looks like it's from a KZ440...is it?

Also, what are those fork seals from?  The bolt at the top...there is no hex, no apparent bolt, and they look recessed....I like it!.  More info?
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Aug 16, 2011, 14:12:52
Nope everything is stock from the kz400 1978 (B)
Title: Re: 78 kz400 cafe build
Post by: reelinfeele on Aug 16, 2011, 18:00:23
I Know you dont have many mikes yet, but how are those rear shocks? I want some.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Aug 16, 2011, 18:11:55
The little bit i have used them they felt really good. much better than stock. time will tell though
I Know you dont have many mikes yet, but how are those rear shocks? I want some.
Title: Re: 78 kz400 cafe build
Post by: stript.714 o/c on Aug 16, 2011, 19:54:13
Man you have nice open roads dude!!! Where do you live???
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Aug 17, 2011, 08:09:42
Yeah that is one nice think about living in the middle of no where. I'm in central Pennsylvania. (Amish country). There is an amazing twisty canyon road about 3 miles from my house. There is some awesome riding out here.
Man you have nice open roads dude!!! Where do you live???
Title: Re: 78 kz400 cafe build
Post by: mcge8241 on Aug 17, 2011, 19:25:44
Glad to see that she's moving!  I was searching thru the thread, and might have missed it, but what grit sandpaper did you use on the aluminum before using the polish?
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Aug 18, 2011, 00:21:09
Yeah you and me both. Jets will be here friday. Then its a trip to the bike shop for inspection then i'm ready to go. For the aluminum I used 220/400/600/1000/polish.

Glad to see that she's moving!  I was searching thru the thread, and might have missed it, but what grit sandpaper did you use on the aluminum before using the polish?
Title: Re: 78 kz400 cafe build (FINISHED pictures!!!!!!!!!!!!!)
Post by: MILLENNIUM FALCON on Aug 20, 2011, 15:32:37
Well.............she's done. The jets cam in friday, I popped them in and she is running great. I put about 20-25 mile on today with no problems. Thanks to everyone for all the help and encouragement.  (http://i1080.photobucket.com/albums/j336/captain_neto/aug2011055.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/aug2011056.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/aug2011057.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/aug2011058.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/aug2011059.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/aug2011060.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/aug2011061.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/aug2011062.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/aug2011063.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/aug2011064.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/aug2011065.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/aug2011066.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/aug2011067.jpg)
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Aug 20, 2011, 15:34:24
(http://i1080.photobucket.com/albums/j336/captain_neto/aug2011068.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/aug2011069.jpg)
Title: Re: 78 kz400 cafe build
Post by: valvesprung on Aug 20, 2011, 16:28:57
A work of art good man, really well done. So what size and specs were the jets? How much of an increase over stock?
Title: Re: 78 kz400 cafe build
Post by: 66replica on Aug 20, 2011, 16:31:29
Lookin' great!
Title: Re: 78 kz400 cafe build
Post by: JustinLonghorn on Aug 20, 2011, 16:48:32
Yes sir. It came out fantastic.
Title: Re: 78 kz400 cafe build
Post by: Shermanator86 on Aug 20, 2011, 18:38:03
Beautiful bike man, looking through this thread pretty much sealed the deal on me wanting to paint my frame red this winter
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Aug 20, 2011, 20:48:07
Stock main is 90 secondary is 70. Im running 108/82

A work of art good man, really well done. So what size and specs were the jets? How much of an increase over stock?
Title: Re: 78 kz400 cafe build
Post by: valvesprung on Aug 20, 2011, 20:51:07
What were the specs/dimensions to order up the secondary that you ended up buying
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Aug 20, 2011, 21:14:03
PJM Jet+carbs part number# Keihin 99101-124 (75f) slow air jet here is the link http://www.pjmotorsports.com/keihin-jets.html#pilot/slow%20jets (http://www.pjmotorsports.com/keihin-jets.html#pilot/slow%20jets)
Title: Re: 78 kz400 cafe build
Post by: reelinfeele on Aug 20, 2011, 21:21:59
Is that one of the jets in back in the opening?
Title: Re: 78 kz400 cafe build
Post by: CBdublin on Aug 20, 2011, 21:26:31
worth the time man. well done. i almost hate when people say this but a future botm imo no doubt. beautiful and love the country road. don't have hills or really much "country" in my town. well done.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Aug 20, 2011, 21:32:28
Its right next to the main jet. it sits down in a little more than the main. Your carbs might be a little different than mine. The best thing to do is pull out your jets see what size they are and measure them and look at PJM"s sizes. I know its a pain but that makes sure you get the right ones. You could look at my pictures to see if we have the same carbs. If you do then Im sure those jets would fit you would just need to know what number size you need for your setup.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Aug 20, 2011, 21:39:25
Thank you, I would love to see my bike get a nomination. Yeah I'm lucky to have back roads. One advantage to living out in the sticks.
worth the time man. well done. i almost hate when people say this but a future botm imo no doubt. beautiful and love the country road. don't have hills or really much "country" in my town. well done.
Title: Re: 78 kz400 cafe build
Post by: PHeller on Aug 20, 2011, 23:27:43
Where you at? Lancaster or Bucks? I'm from Marietta, which is towards Columbia in Lancaster, PA.
Title: Re: 78 kz400 cafe build
Post by: Syke on Aug 21, 2011, 00:23:59
For some reason I was under the impression he lived somewhere between Harrisburg and State College.  Gorgeous riding country up there (so says an ex-Johnstown boy).
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Aug 21, 2011, 08:11:57
Yup skye is correct. I live  between williamsport and state college. I'm about 25 minutes from the Little League world series.
Where you at? Lancaster or Bucks? I'm from Marietta, which is towards Columbia in Lancaster, PA.
Title: Re: 78 kz400 cafe build
Post by: stript.714 o/c on Aug 24, 2011, 22:28:36
Yeah that is one nice think about living in the middle of no where. I'm in central Pennsylvania. (Amish country). There is an amazing twisty canyon road about 3 miles from my house. There is some awesome riding out here.
Thats awesome i have to play russian rulet when i ride !
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Aug 27, 2011, 16:31:42
My dad and I went on a little longer ride today. She ran great. Passed Inspection. My poor wiring skills worked well enough to get a sticker ;D The only thing that suck, is that somewhere between my house and the bike shop I lost a mirror. :( (http://i1080.photobucket.com/albums/j336/captain_neto/102_5080.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/102_5079.jpg)
Title: Re: 78 kz400 cafe build
Post by: bikeboy on Aug 28, 2011, 08:05:09
excellent work. Another hurdle successfully negotiated  ;D


cheers
ian
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Sep 03, 2011, 01:33:46
I made a new bushing for the mirror I still have (so it fits in the bars better) so now I need to decide.....do I want to order another mirror to match or do I want to get new mirrors all together??? I also thought about just running one mirror and making brass bar end for the other side that would hold my rolled up registration and insurance cards. What do you think? I also have a wobble from the front tire. I thought I needed to true up the wheel but when I put the indicator on it I only had .006 runout that is well within specs.  Then I notice while sppining the wheel that the runout was in the tire. It almost looks like the bead on the tire sits deeper into the rim in one spot than another. The tires are brand new avons and the tubes are new and the correct size. Psi is good. I tried deflating the tire and making sure the tire is sitting where it should. Any thought/suggestions? It's not that far out, just enough to bug me. Thanks
Title: Re: 78 kz400 cafe build
Post by: 1976cb356 on Sep 03, 2011, 02:20:31
huh, it sounds like u did everything right, thats what happened to my friends rear wheel. I like the idea of the rolled up insurance papers in the bars.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Sep 03, 2011, 09:27:08
Yeah I don't get it. My only thought is that I either got a bad tire or a mismarked tube. I really hope it's not the tire. $125. Any ideas????
Title: Re: 78 kz400 cafe build
Post by: MotorbikeBruno on Sep 07, 2011, 20:07:42
Did you happen to use tire lube (insert joke here)  ;D

I found that mine did the same unless I lubed them up good.  I heard you should NOT use soap and water because of some chemicals in soap that can eat away at the rims. Not sure if it's true, but I bought some tire lube at my local shop and have been happy since!  Hope that works for ya.

Bruno
Title: Re: 78 kz400 cafe build
Post by: Maritime on Sep 07, 2011, 20:12:37
It's Always better with Lube ;D
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Sep 07, 2011, 20:20:35
I think I got it all figured out. I put about 5psi in the tire and rolled it around the driveway for awhile. I pumped it up and now it seems fine. I prefer to go lube free, (for the tire of course) ;)
Title: Re: 78 kz400 cafe build
Post by: MotorbikeBruno on Sep 08, 2011, 10:17:09
Glad to hear you've got it figured out.   ;D
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Sep 08, 2011, 18:17:09
Yeah I guess it just wasnt seated all the way........ ???
Title: Re: 78 kz400 cafe build
Post by: MotorbikeBruno on Sep 08, 2011, 18:43:02
It happens...in fact it happened to me today!  And I brought it in to the dealer by me....I got lazy and didn't want to do it on my friends ninja 250, they couldn't get it to seat at all!  I told them to put a tube in it and pump it up and let it sit for an hour or so, they called after 2 hours and said the trick worked!  Tire must have been on a pallet or something weird. 

Get some more miles on that thing now!!
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Sep 08, 2011, 19:28:09
I plan on it! if it ever stops raining. We have been having flooding. Over 7" in the last 3 days
It happens...in fact it happened to me today!  And I brought it in to the dealer by me....I got lazy and didn't want to do it on my friends ninja 250, they couldn't get it to seat at all!  I told them to put a tube in it and pump it up and let it sit for an hour or so, they called after 2 hours and said the trick worked!  Tire must have been on a pallet or something weird. 

Get some more miles on that thing now!!
Title: Re: 78 kz400 cafe build
Post by: MotorbikeBruno on Sep 09, 2011, 13:34:41
Yikes.  We've been dipping into the 40's here and there at night again  :(   Minnesnowta is keeping up it's wintery name again...EF.
Title: Re: 78 kz400 cafe build (Riding)
Post by: MILLENNIUM FALCON on Sep 13, 2011, 22:09:32
I went on a nice little ride today. Put on a few miles. I took my GPS to check the airspeed. It was pretty close. 30 on the air speed 33ish on the gps. I am working on a better rubber mount because the needle jumps alot at high RPM. I'm just pleased that it works. I had her up to 72mph on the gps, no problem.
Title: Re: 78 kz400 cafe build
Post by: Shermanator86 on Sep 20, 2011, 16:06:28
So how are those rear shocks treating you after you've put some more mile on them?
Title: Re: 78 kz400 cafe build
Post by: schaubster on Sep 21, 2011, 18:24:36
how did i miss this bike?
Title: Re: 78 kz400 cafe build
Post by: schaubster on Sep 21, 2011, 18:25:02
one of the best i've seen.
Title: Re: 78 kz400 cafe build
Post by: MotorbikeBruno on Sep 21, 2011, 18:32:13
I voted!  ;)
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Sep 21, 2011, 19:56:19
They are GREAT! so much better than stock and then some. I would recommend. I dont have too many miles on them yet but so far so good.
So how are those rear shocks treating you after you've put some more mile on them?
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Sep 21, 2011, 19:57:25
Thank you guys for all the support. I'm still surprised some one likes something I built.  ???
how did i miss this bike?
Title: Re: 78 kz400 cafe build
Post by: Syke on Sep 21, 2011, 21:05:37
At which point you're going to start getting delusions of competency.
Title: Re: 78 kz400 cafe build
Post by: Shermanator86 on Sep 21, 2011, 21:12:25
They are GREAT! so much better than stock and then some. I would recommend. I dont have too many miles on them yet but so far so good.


Good to hear, might be the next item on the list for my 78 haha. and also voted for your bike as your build is the whole reason i found this site, was searching for 78 kz400 cafe bikes and yours popped up on google been following the build ever since
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Sep 21, 2011, 21:38:26
 Haha.... Maybe when something I build makes me money instead of costing me money.
At which point you're going to start getting delusions of competency.
Title: Re: 78 kz400 cafe build
Post by: PatDoody on Sep 21, 2011, 23:07:46

Good to hear, might be the next item on the list for my 78 haha. and also voted for your bike as your build is the whole reason i found this site, was searching for 78 kz400 cafe bikes and yours popped up on google been following the build ever since

haha same reason I found it as well! I was looking at a kz400 for sale and was trying to find cool stuff to do to it. I wound up with an xs650 but still followed the thread, lots of good ideas here.
Title: KZ400 cafe (Thank you!!)
Post by: MILLENNIUM FALCON on Oct 02, 2011, 02:20:14
I just want to say thank you to everyone on DTT for following my build. I couldnt have done it without all the comments and tips. You guys kept me motivated. Being chosen for BOTM really finishes this build for me. Thanks again. ;D ;D ;D ;D
Title: Re: 78 kz400 cafe build
Post by: stript.714 o/c on Oct 21, 2011, 12:07:11
Yo man congradulations on botm,it was cool to see the bike go threw the proses!!
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Oct 21, 2011, 14:03:15
Thanks man! Thanks for watching. How is your rebuild going? It was a real shame to see your beautiful bike get smashed up.
Title: Re: 78 kz400 cafe build
Post by: stript.714 o/c on Oct 21, 2011, 16:52:30
Its going a little slow do to cash,but it is going. It sounds really funny ,and dumb to say but,i was so devistated laying on the ground looking at the bike smashed in to the car,even though i should of been more conserned about my broken ankle!
 Some thing about refurbeshing an old bike you are just willing to sacrefice your body for the bike lol you cant help to think no not my bike!!!lol
 Congrats again brother!
Title: Re: 78 kz400 cafe build
Post by: Fox on Jan 24, 2012, 00:20:01
This thing looks clean. Very well done.
Title: Re: 78 kz400 cafe build
Post by: grgaSH on Apr 17, 2012, 21:40:15
!nice project, looks simple and orderly  ;)
Title: Re: 78 kz400 cafe build
Post by: two-smoker on Apr 26, 2012, 09:33:39
Just saw your bike in Cafe Racer Magazine... Funny how many bikes from DTT end up in those pages. Good on ya!
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Apr 26, 2012, 13:27:40

Thanks man. Dtt members make some of the coolest bike on the road.


Just saw your bike in Cafe Racer Magazine... Funny how many bikes from DTT end up in those pages. Good on ya!
Title: 78 kz400 cafe build
Post by: Ryanh on Jul 10, 2012, 10:25:12
Just read the whole build, love it
Title: Re: 78 kz400 cafe build
Post by: andycafe on Jul 11, 2012, 08:07:13
very cool man, came up ducks!
Title: Re: 78 kz400 cafe build
Post by: veaone on Aug 01, 2012, 01:49:41
What an amazing build and craftsmanship.
Title: Re: 78 kz400 cafe build
Post by: Autotek on Oct 23, 2012, 23:26:46
Im surprised I haven't seen this, great job it looks awesome!
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Oct 23, 2012, 23:55:59
Man it has been awhile since I have seen anyone comment on this thread. Its good to know people are still checking it out. Thanks man! I have been riding and enjoying this bike ever since it hit the road.


Im surprised I haven't seen this, great job it looks awesome!
Title: Re: 78 kz400 cafe build
Post by: BLSully on Oct 26, 2012, 15:10:22
Millenium.... i just found this build through the VM30 group buy thread. There are no words. This things is fantastic. I'm in the process of doing a KZ400 this winter and you're build is very inspirational. Just wish I had access to as many tools  :'(
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Oct 26, 2012, 15:22:41
Thanks man! Its always good to hear that other people are building Kz's. The right tools do make all the difference in the world. Good luck on your build!
Title: Re: 78 kz400 cafe build
Post by: sovern on Nov 17, 2012, 04:14:53
(http://i1080.photobucket.com/albums/j336/captain_neto/lace005.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/lace006.jpg)
What's with the wrinkle paint? Why not a gloss - I'm curious because I mistook it for grime at first, had to go back and re-read. Maybe it looks nicer in person?
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Nov 17, 2012, 09:00:18
I personally think it looks nice in person. I think the wrinkle finish really adds a look of quality. I have found gloss spray paint to look kinda cheap especially if it is not done correctly. This area was very hard to prep so I think it would have looked cheap if it was gloss. I defiantly wasn't going to polish this entire area. To each his own I guess.
Title: Re: 78 kz400 cafe build
Post by: sovern on Nov 17, 2012, 11:37:38
I personally think it looks nice in person. I think the wrinkle finish really adds a look of quality. I have found gloss spray paint to look kinda cheap especially if it is not done correctly. This area was very hard to prep so I think it would have looked cheap if it was gloss. I defiantly wasn't going to polish this entire area. To each his own I guess.
Hm I'm really curious. I want to see it in person. I might pick up a can of that wrinkle paint and try it out. I'm assuming an advanced auto or pepboys would carry it? Also, any particular reason you didn't make your own handlebars? If I'm remembering correctly, you mentioned something about welding?
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Nov 17, 2012, 12:24:03
I wanted stainless steel and I found a guy who could tig weld them and ship them to me for less than the cost of materials if i were to do it myself. So that was a no brainier. Yes you can buy the paint at advanced auto.
Title: Re: 78 kz400 cafe build
Post by: sovern on Nov 17, 2012, 12:25:18
I wanted stainless steel and I found a guy who could tig weld them and ship them to me for less than the cost of materials if i were to do it myself. So that was a no brainier. Yes you can buy the paint at advanced auto.

Oh nice. Any advantage to stainless steel bars? I only ask because I want to make my own with specific angle and everything. Thanks!
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Nov 17, 2012, 12:33:50
Stronger/lighter/they don't rust/they look amazing......nuf said?
Title: Re: 78 kz400 cafe build
Post by: sovern on Nov 17, 2012, 12:34:23
Stronger/lighter/they don't rust/they look amazing......nuf said?

good points. Thanks! Sent you a PM.
Title: Re: 78 kz400 cafe build
Post by: napalm666 on Aug 06, 2013, 17:54:57
Stock main is 90 secondary is 70. Im running 108/82

Great looking bike! I had a question for you. What do you mean by "108/82"?
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Aug 06, 2013, 20:17:10
Thanks napalm. I was refering to the carb jets. I used 108 main jet and 82 pilot jet. I hope this helps. Let me know. Thanks.
Title: Re: 78 kz400 cafe build
Post by: napalm666 on Aug 06, 2013, 20:32:22
Ahhh... I see now. You were saying the stock were 90 and 70 and that you were using 108 and 82. My bad. I didn't understand at first. Thanks you so much. I'm gonna give those numbers a try.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Aug 06, 2013, 20:56:04
It runs quite good but I might try to go a little richer on the main. Probably like a 112-115 on the main jet.
Title: Re: 78 kz400 cafe build
Post by: napalm666 on Aug 06, 2013, 21:01:18
So you replaced the 90 with 108 an the 70 with 82? Did you change out your pilot? I'm sorry for so many questions. We pretty much have the exact same set up and I've been looking everywhere for answers and this is the closest I've come.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Aug 06, 2013, 21:07:51
Yup, I did exactly what you described. It runs great but I think it has a little more potential on te top end. It's always best to stay on the Rich side.
Title: Re: 78 kz400 cafe build
Post by: napalm666 on Aug 06, 2013, 21:17:51
So you didn't change the pilots at all?
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Aug 06, 2013, 21:19:55
Yes.... The stock pilot was 70..I changed it out with the 82.
Title: Re: 78 kz400 cafe build
Post by: napalm666 on Aug 06, 2013, 21:51:08
I apologize. I'm confused now. Haha... So you changed both the main and the secondary main to the 108? But then changed the pilots to the 82. Did I get that correct? Basically I should get 4 main jets to replace the the 4 90 mains and 2 82 pilots to replace the 2 70? Again, I apologize.
Title: Re: 78 kz400 cafe build
Post by: napalm666 on Aug 06, 2013, 22:13:50
http://www.kz400.com/TechnicaltipsFrameset.html

So #60 and #65 on the diagram would be changed to 108- 115? And #61 would be 82?

Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Aug 06, 2013, 23:02:05
Haha carbs are confusing. The link didn't work for me but.....no. I only changed the main jets and pilot or "slow jet". So I only changed two jets per carb. That is all you need to do most of the time ( with mild mods) at least that has been my experience. So in each carb I changed my main jet to 108 and my pilot or "slow jet" to 82. So to do the whole job I bought 4 jets. A total of about $18. Others may have a different opinion on this. I am not an expert by any means. There are also some really good threads on here about jetting and tuning. They really helpe me while I was learning. I hope this cleared things up for you. It really is easy once you tinker around with jetting a bit.
Title: Re: 78 kz400 cafe build
Post by: napalm666 on Aug 06, 2013, 23:55:55
Haha... Right on. Well the diagram I had a link to was showing that there was a main jet, secondary main jet, and a pilot jet (slow) that has a little rubber plug that goes in with it. I didn't know if you changed all of them or what.

I use to own a 74 cb750 that had pods and needed re jetted, and I did, but for some reason that seemed easier. Maybe because there wasn't a main and a secondary and blah blah. But the big issue with me is I don't want to spend a ton of money on all these jets trying to figure out which ones work and which don't an end having like $60 in parts I don't need. Haha... Oh well, I guess you gotta pay to play...

Thanks again for your time. I'll just order a few and see what works best.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Aug 07, 2013, 09:45:03
What year is your bike? I know the kz's came with two different style carbs.
Title: Re: 78 kz400 cafe build
Post by: napalm666 on Aug 07, 2013, 14:47:21
1978 kz400 b1.
Title: Re: 78 kz400 cafe build
Post by: napalm666 on Aug 07, 2013, 15:01:38
Also, how are those rear shocks working out for you? I was thinking of getting a pair.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Aug 07, 2013, 18:41:13
Huh....yeah, the carbs should be the same. So far I am happy with my shocks. MUCH better than stock.
Title: Re: 78 kz400 cafe build
Post by: napalm666 on Aug 08, 2013, 00:23:03
Yeah, I figured they were. Like I said, I'll just have to get a few and try em out.

I might have to get me a set of those shocks. Budgets low at the moment, but I'll get em eventually.

Thanks again for you're time. I really do appreciate it.
Title: Re: 78 kz400 cafe build
Post by: Chuck.leis on May 02, 2014, 08:30:22
Amazing build!  I've been cruising DTT and the rest of the interwebs for the last few months looking for inspiration for my upcoming build. I have a 79 kz400 that I have started collecting pieces for. I ran across pics of your bike in a google search and drooled all over them. Saved a couple to my phone to show people what I wanted to do to mine actually lol. About the 30th time I looked at the article the google pics linked to I noticed it had a link to your build thread here!  So I just blazed through it. Outstanding.   Your build just became the  #1 inspiration for mine.
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on May 14, 2014, 01:34:22
Wow that really means a lot  man! Thanks..... I did the same thing when I was building my bike. I'm glad my creation can help someone else finish theirs. Good luck to you.


Amazing build!  I've been cruising DTT and the rest of the interwebs for the last few months looking for inspiration for my upcoming build. I have a 79 kz400 that I have started collecting pieces for. I ran across pics of your bike in a google search and drooled all over them. Saved a couple to my phone to show people what I wanted to do to mine actually lol. About the 30th time I looked at the article the google pics linked to I noticed it had a link to your build thread here!  So I just blazed through it. Outstanding.   Your build just became the  #1 inspiration for mine.
Title: Re: 78 kz400 cafe build
Post by: Nduetime on Sep 26, 2014, 01:30:32
I rebuilt my Master cylinder, mounted my caliper and installed new hose and fittings. One more thing off the list!!! 8) (http://i1080.photobucket.com/albums/j336/captain_neto/001-7.jpg)(http://i1080.photobucket.com/albums/j336/captain_neto/002-10.jpg)

Out of curiosity, how did the banjo bolt/pressure switch work out for you? From the photos it looks like it allowed you to ditch the three way splitter behind the headlight and run a brake line from the master cylinder all the way to the caliper (no pipe bride either?) I suppose this allowed for the added clearance to drop the headlight all the way down?
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Feb 19, 2015, 21:53:56
Yes I really like the switch. It allowed me to get rid of the 3way splitter and cleaned up the look a lot.
Title: Re: 78 kz400 cafe build
Post by: Daroska on Jan 30, 2016, 16:55:17
Aloha Millennium

I'm so glad U referred me to Ur build.  What a great build to read & a cool bike.  Congrats on the BOTM award.

I must say , I believe Ur grandfather would be proud of the skill U have shown in the use of his tools ! !   Great work 👍🏻

I don't ride anymore but Ur thread has made me want to go out & get a bike to build.

     😎🌴
Title: Re: 78 kz400 cafe build
Post by: MILLENNIUM FALCON on Jan 31, 2016, 00:28:58
Thank you Daroska! That means a lot to me. sounds like you need to build something so you can get back out riding again!

Aloha Millennium

I'm so glad U referred me to Ur build.  What a great build to read & a cool bike.  Congrats on the BOTM award.

I must say , I believe Ur grandfather would be proud of the skill U have shown in the use of his tools ! !   Great work 👍🏻

I don't ride anymore but Ur thread has made me want to go out & get a bike to build.

     😎🌴