DO THE TON

Blood Sweat Tears and Grease => Projects => Cafe Racers => Topic started by: 7aliveatlast7 on Jun 12, 2012, 12:11:42

Title: '81 kz440: brat cafe build
Post by: 7aliveatlast7 on Jun 12, 2012, 12:11:42
i'm new here from customfighters.com.  my '81 kz440 project is well underway, but all the work done thus far has been on that site.  however, i grabbed some progress pics off there to make somewhat of a timeline for you all so you can see what i've been up to with this thing for the last year and a half!

this is how i bought it, as a "cool idea but pretty ugly" bobber...

(http://pic100.picturetrail.com/VOL1165/13336731/23780628/398123026.jpg)

i had a set of gsxr forks and kawi zx6r wheel waiting to be used, so i threw them on...

(http://pic100.picturetrail.com/VOL1165/13336731/23780628/398123027.jpg)

got some beefier tires, ditched the dirt bars and went with clip ons, scored a front brake setup on ebay, and a set of progressive shocks, which were desperately needed.  the PO had cut the original rear springs, so not only was there ZERO travel in them, but the springs were working their way up over the upper bump stop.  this is what i ended up with after all that went on...

(http://pic100.picturetrail.com/VOL1165/13336731/23780628/398123402.jpg)

as you can see from that pic, the front tire looks HUGE compared to the rear.  that's because the zx6 wheel was wider than the original kz wheel in the back, so even though both tires were a 120 width with the same size sidewall, the wider wheel up front allowed it to expand more.  also, the rear wheel was an 18", while the zx6 wheel was 17", so something had to be done.  ebay to the rescue.  $100 later got me this whole setup...

(http://www.customfighters.com/forums/imagehosting/105384e5681b1818e7.jpg)

that's the rear wheel off a 2010 ex250.  17" like the front, slightly wider, and the spoke patter now matched haha.

so, that takes us up to last december, a little over a year of having the bike.  work was slow because i was able to ride it all last season, so i didn't do any work during that time.  but once it started to get cold, i wrapped the pipes, threw on some shorty levers (hard to see in pic) and finally got the new rear wheel on...

(http://www.customfighters.com/forums/imagehosting/105384edaa3547916f.jpg)

the stock swingarm wasn't wide enough to accept the new rear wheel, so my wife got me an ex250 rear swinger to match the wheel for Christmas :)  i then started entertaining the idea of monoshocking it...

(http://pic100.picturetrail.com/VOL1165/13336731/23780628/400522686.jpg)

over the winter i cut up the tank and made an attempt at some knee dents.  also made my own exhaust (except the muffler, that i bought).  but, as you can see from the pics, it was way too close to my rear end! 

(http://pic100.picturetrail.com/VOL1165/13336731/23780628/401056958.jpg)

(http://pic100.picturetrail.com/VOL1165/13336731/23780628/401056959.jpg)

so that had to be re worked.  a lot has been done since then, but not much has been done as far as picture documentation.  as a landscaper, i had planned to be laid off over the winter, so i tore into a bunch of stuff on the bike that i thought i'd have time to complete by spring.  however, here in PA it never got cold enough for long enough, so we worked straight through the winter, and i ended up not having nearly the amount of time with the bike that i thought i would.  so that leaves it in it's current state:  exhaust nearly done, monoshock setup nearly done, engine painted and mostly hooked back up, seat still needing to be completed.  a lot of little things, but hopefully it will be wrapped up by july.  much later than i wanted, but what are you gonna do haha. 

anyhow, that's my bike!  i'm excited to be a part of this community now, and i can't wait to show you all progress as it comes!
Title: Re: '81 kz440: bobber --> cafe
Post by: tron97 on Jun 12, 2012, 13:54:19
Sweeet..I remember seeing this bike somewhere else..

So are you going to monoshock it?
Title: Re: '81 kz440: bobber --> cafe
Post by: 7aliveatlast7 on Jun 12, 2012, 14:08:17
it's been on customfighters.com, so you may have seen it there.  i am in the process of monoshocking it, yes.  well, a buddy of mine is doing the welding for me, as all i have access to is a little flux core mig, and there's no way that could do the job haha.  can't wait for it to be done though, i'm super pumped!
Title: Re: '81 kz440: bobber --> cafe
Post by: Shermanator86 on Jun 12, 2012, 14:22:43
Looks like it will be a cool kz, I'll be watching this one
Title: Re: '81 kz440: bobber --> cafe
Post by: CafeRacer650 on Jun 12, 2012, 14:47:21
Good looking bike!  It has the look of a Confederate.  I would almost keep that "raw material" feel and not paint the tank.  If you want to go crazy and keep that detached look on the rear wheel, try to put a Britten rear suspension setup on it.  That would make a rockin' ride!!
Title: Re: '81 kz440: bobber --> cafe
Post by: AdrockMK2 on Jun 12, 2012, 15:03:32
Looks awesome! I liked the powder blue with the chunky black...are you going to paint the tank?
Title: Re: '81 kz440: bobber --> cafe
Post by: 7aliveatlast7 on Jun 13, 2012, 12:49:26
I would almost keep that "raw material" feel and not paint the tank.

Looks awesome! I liked the powder blue with the chunky black...are you going to paint the tank?

i'm having a hard time deciding between those two options of leaving it raw or painting it.  i love the raw, more industrial look, but i also love color, so we'll see what happens, ha. 

on another note, i couldn't be happier about this little dandy...

(http://pic100.picturetrail.com/VOL1165/13336731/23780628/403017731.jpg)

this baby came courtesy of cafegoose.  for months now i have been looking for a loop like this to cap off the back end of my bike, and for the life of me, i could not find one that wasn't upwards of $100.  cafegoose has these for half that + FREE SHIPPING.  and speaking of shipping, i talked to him about it thursday, he shipped it out last friday and i had it by monday.  can't beat that!  thanks goose!
Title: Re: '81 kz440: bobber --> cafe
Post by: M.B Co on Jun 13, 2012, 14:22:52
Hell ya, so sick.

So whats the specs on the GSXR front.  I have my eyes on a front setup at a local salvage yard.
Title: Re: '81 kz440: bobber --> cafe
Post by: Shermanator86 on Jun 13, 2012, 15:07:25
Hell ya, so sick.

So whats the specs on the GSXR front.  I have my eyes on a front setup at a local salvage yard.

I was wondering that myself, whats all involved in switching to modern forks like that?
Title: Re: '81 kz440: bobber --> cafe
Post by: DesmoBro on Jun 13, 2012, 15:13:12
I was wondering that myself, whats all involved in switching to modern forks like that?

If the stem is the same length (usually not the case) they can switch over with new bearings....If the stem is a shorter/longer, you must have the old stem pressed out/and the new tripples are machined to fit the old stem with Very tight toleranced bushings, Then new bearings....
Title: Re: '81 kz440: bobber --> cafe
Post by: 7aliveatlast7 on Jun 13, 2012, 16:42:23
if you need help, go to allballsracing.com.  they have a fork conversion chart where you can just put in the make and model of your bike and they'll give you a whole list of other makes and models who's forks are compatible with your bike.  it just so happened that my forks off a gsxr750 were a perfect fit for my kz440.  oddly enough, had i ended up with a set of forks off a gsxr600 or 1000, they would NOT have fit and i would've needed new bearings.  the only thing i ended up having to switch was the bottom race off the original forks onto the new ones, then i used all the same bearings.  the stem is a bit long, but i didn't feel like going through the trouble of finding a shop and paying them to press the stems out and in.  the longer stem just took a spacer to fix.
Title: Re: '81 kz440: bobber --> cafe
Post by: Shermanator86 on Jun 13, 2012, 17:18:19
if you need help, go to allballsracing.com.  they have a fork conversion chart where you can just put in the make and model of your bike and they'll give you a whole list of other makes and models who's forks are compatible with your bike.  it just so happened that my forks off a gsxr750 were a perfect fit for my kz440.  oddly enough, had i ended up with a set of forks off a gsxr600 or 1000, they would NOT have fit and i would've needed new bearings.  the only thing i ended up having to switch was the bottom race off the original forks onto the new ones, then i used all the same bearings.  the stem is a bit long, but i didn't feel like going through the trouble of finding a shop and paying them to press the stems out and in.  the longer stem just took a spacer to fix.

Thanks for the info, I need new forks sometime as mine are too pitted to be saved and the search for cheap replacements hasn't turned up much so might as well upgrade haha.

I'll be watching this build for sure though
Title: Re: '81 kz440: bobber --> cafe
Post by: 7aliveatlast7 on Jun 13, 2012, 18:14:54
Thanks for the info, I need new forks sometime as mine are too pitted to be saved and the search for cheap replacements hasn't turned up much so might as well upgrade haha.

I'll be watching this build for sure though

what kind of bike do you have?  i still have the forks from my kz if you'd be interested.  or if you're patient, some real gems pop up on ebay here and there.  i got my forks with the top and bottom yokes for $180, which from what i've seen is a decent deal.
Title: Re: '81 kz440: bobber --> cafe
Post by: Shermanator86 on Jun 14, 2012, 16:48:45
what kind of bike do you have?  i still have the forks from my kz if you'd be interested.  or if you're patient, some real gems pop up on ebay here and there.  i got my forks with the top and bottom yokes for $180, which from what i've seen is a decent deal.

might be interested in those kz forks, they should be the same as mine. PM me some pics and info if you would
Title: Re: '81 kz440: bobber --> cafe
Post by: SeaBee on Jun 14, 2012, 17:15:48
Saw the build title and was thinking, meh not interested...

Saw the build and I'm in! 
Title: Re: '81 kz440: bobber --> cafe
Post by: Bobbed_out on Jun 14, 2012, 17:26:38
Sweet kz...
Title: Re: '81 kz440: bobber --> cafe
Post by: Erskine on Jun 14, 2012, 17:59:53
Saw the build title and was thinking, meh not interested...

Saw the build and I'm in! 

+1
Didn't expect that!
Title: Re: '81 kz440: bobber --> cafe
Post by: 7aliveatlast7 on Jun 15, 2012, 01:35:02
dangit, maybe i need to change the title of my thread haha!  glad it's a nice surprise once people take a look though :)
Title: Re: '81 kz440: bobber --> cafe
Post by: 7aliveatlast7 on Jun 25, 2012, 13:35:11
alright, so progress has been slow lately, but last night i went to my buddy's place who's welding up the monoshock mounts for me and we put in some good work!  2-3 more hours on it this coming saturday should see it FINALLY finished!!  i forgot my camera, so i didn't get any pics of the work.  however, we pulled out the piece of wood i was using to hold the rear up (as seen in previous pics) so we could get in there to weld some stuff, and my buddy snapped these pics with his phone of what it would look like with a serious bob job, haha.  bobbers were my first love, what first got me interested in modding bikes, so it was tempting to see it like this.  however, i'm way too far into my cafe planning to even consider changing directions, so it'll have to wait for another build!  looks sweet though, in my opinion...

(http://pic100.picturetrail.com/VOL1165/13336731/23780628/403177843.jpg)

(http://pic100.picturetrail.com/VOL1165/13336731/23780628/403177841.jpg)

anyhow, i also got some more little bits to install soon:

lowbrow customs baffles...

(http://pic100.picturetrail.com/VOL1165/13336731/23780628/403177969.jpg)

and some translucent neon yellow fuel line tubing.  nothing super exciting, but progress nonetheless!  neon is not my thing, but since my bike is gonna be pretty drab colors, i thought a little flair of an accent color could look cool. 

Title: Re: '81 kz440: bobber --> cafe
Post by: tron97 on Jun 26, 2012, 20:34:10
Sweet cant wait to see it.

I used lowbrows baffles in mine, did the trick. Took the edge off

Title: Re: '81 kz440: bobber --> cafe
Post by: 7aliveatlast7 on Jun 27, 2012, 10:59:39
Sweet cant wait to see it.

I used lowbrows baffles in mine, did the trick. Took the edge off

oh nice!  i searched all over to try and find a video of someone using them, but no luck.  you happen to have any of your bike running with them?
Title: Re: '81 kz440: bobber --> cafe
Post by: 7aliveatlast7 on Jun 30, 2012, 13:43:20
so not a great pic, but just taken quickly of today's work.  shock mounts are in!  monoshock is bolted up!  only thing left to do is box in the top mounts, but that'll take no time at all.  hopefully gonna do that monday night, and possibly finish welding up the exhaust then too.  everythings kind of a mess right now, with wiring everywhere and a bunch of spots on the frame ground bare, or needing to be ground down, so i'll be working on that too. 

(http://pic100.picturetrail.com/VOL1165/13336731/23780628/403244468.jpg)
Title: Re: '81 kz440: bobber --> cafe
Post by: 7aliveatlast7 on Jul 03, 2012, 11:11:41
moved all the clutter outta the way so we could finish up the top mount.  boxed in, finished.  next project will be the frame loop on the back.

(http://pic100.picturetrail.com/VOL1165/13336731/23780628/403277523.jpg)
Title: Re: '81 kz440: bobber --> cafe
Post by: JustinLonghorn on Jul 03, 2012, 11:19:54
I can dig it.
Title: Re: '81 kz440: bobber --> cafe
Post by: 7aliveatlast7 on Jul 09, 2012, 12:07:31
some weekend progress...

(http://pic100.picturetrail.com/VOL1165/13336731/23780628/403337544.jpg)

(http://pic100.picturetrail.com/VOL1165/13336731/23780628/403337543.jpg)

(http://pic100.picturetrail.com/VOL1165/13336731/23780628/403337542.jpg)
Title: Re: '81 kz440: bobber --> cafe
Post by: 7aliveatlast7 on Jul 26, 2012, 16:32:30
so i'm pickin up my buddy's welder again tomorrow.  i'm gonna finish tacking the exhaust up, then i'm going to take it somewhere to get it finish TIG'd.  i just don't trust the flux core MIG welds to hold, ha.  anyone ever made their own exhaust and used a gas MIG setup on it?  if so, how did it hold?  i figured i'd try to get it TIG'd because it's a nicer finish, but as far as strength, how do the 2 compare?  i do have a friend with a gas MIG welder, and that would be much more convenient, but would TIG be a better option in the long run? 
either way, work will be getting done come saturday, so i'm excited.  i'm also trying to find some old seat foam to cut down for my bike's new seat.  i really don't want to go to the local bike yard for a seat because the guy is kind of a rip, i'm sure he'll charge me more than i'm looking to spend for even the most ratty old seat.  i just want the foam, man!
oh, i also stripped the paint off the tank last weekend and i'm trying to figure what route i want to go.  i'm thinking of just flash rusting it a very little bit, clear coating it, slappin some kawi emblems on the side and rocking it like so.  we'll see.  progress to come... 
Title: Re: '81 kz440: bobber --> cafe
Post by: SloKrt on Jul 26, 2012, 23:59:30
Sweet build!  Kinda the same direction I'm headed.  Can't wait to see the finished product. 

I'm in. 
Title: Re: '81 kz440: bobber --> cafe
Post by: smeyer on Jul 27, 2012, 00:07:23
I love the bike and also have a 440.  Did you make any Carb changes for the pods and open exhaust?  I am struggling with that now.
Title: Re: '81 kz440: bobber --> cafe
Post by: dmrhoades on Jul 27, 2012, 12:12:27
so i'm pickin up my buddy's welder again tomorrow.  i'm gonna finish tacking the exhaust up, then i'm going to take it somewhere to get it finish TIG'd.  i just don't trust the flux core MIG welds to hold, ha.  anyone ever made their own exhaust and used a gas MIG setup on it?  if so, how did it hold?  i figured i'd try to get it TIG'd because it's a nicer finish, but as far as strength, how do the 2 compare?  i do have a friend with a gas MIG welder, and that would be much more convenient, but would TIG be a better option in the long run? 
either way, work will be getting done come saturday, so i'm excited.  i'm also trying to find some old seat foam to cut down for my bike's new seat.  i really don't want to go to the local bike yard for a seat because the guy is kind of a rip, i'm sure he'll charge me more than i'm looking to spend for even the most ratty old seat.  i just want the foam, man!
oh, i also stripped the paint off the tank last weekend and i'm trying to figure what route i want to go.  i'm thinking of just flash rusting it a very little bit, clear coating it, slappin some kawi emblems on the side and rocking it like so.  we'll see.  progress to come... 
great minds think alike...I had the same idea, this pic is what mine looks like. The flash rust is a bit hard to see in the photo though
(http://i159.photobucket.com/albums/t121/davidrhoades/photobucket-2545-1343401537585.jpg)
Title: Re: '81 kz440: bobber --> cafe
Post by: 7aliveatlast7 on Jul 27, 2012, 13:51:13
I love the bike and also have a 440.  Did you make any Carb changes for the pods and open exhaust?  I am struggling with that now.

thanks!  i didn't make any carb changes because i bought it with pods already installed, and the 2-1 exhaust that was on it was already hacked by the PO.  i'm sure i'll need to tune it to the straight pipes once they're done, though i'm hoping it won't be a terrible struggle since it already had a pretty open exhaust when i bought it.  are you running any baffles? 

great minds think alike...I had the same idea, this pic is what mine looks like. The flash rust is a bit hard to see in the photo though
(http://i159.photobucket.com/albums/t121/davidrhoades/photobucket-2545-1343401537585.jpg)

wow, that things a beauty!  definitely a good argument for keeping the tank bare!  and i like the use of the lad as a kickstand  ;D
Title: Re: '81 kz440: bobber --> cafe
Post by: dmrhoades on Jul 27, 2012, 13:54:48
haha thanks..the side stand on these things make taking pics very difficult
Title: Re: '81 kz440: bobber --> cafe
Post by: 7aliveatlast7 on Jul 31, 2012, 21:00:26
so today i went to the local "you pull it" yard in search of some good, firm seat foam for my seat.  i ended up getting the entire bottom of a front seat in perfect shape for $4.24!  got it home and got the turkey knife out and went to town.  please pardon the awful cell phone pic, but this'll give an idea of what it will look like.  the vinyl came off an old bench press set my parents had in their garage.  dad pulled it from the trash years ago, and it's finally getting used for something, ha! just pulled some of the material loosely over the seat to get an idea...

(http://pic100.picturetrail.com/VOL1165/13336731/23780628/403537108.jpg)
Title: Re: '81 kz440: bobber --> cafe
Post by: dmrhoades on Jul 31, 2012, 21:09:53
Lookin good!
Title: Re: '81 kz440: bobber --> cafe
Post by: CafeRacer650 on Aug 01, 2012, 10:13:50
Looks awesome dude!  Looking forward to seeing your progress!
Title: Re: '81 kz440: bobber --> cafe
Post by: 7aliveatlast7 on Aug 05, 2012, 19:07:25
little seat update.  so i wanted a seat pan i could staple into once i was ready to stretch my cover around it, and i knew the best way to do that would be to make it out of abs plastic.  i scratched my head trying to think of where to get such a big, flat piece as i needed, and finally it came to me...50 gallon drum.  my in-laws happened to have an old one laying around, and they said it was all mine if i wanted it, so i got to cutting it up.  it's nice and thick, and the only problem with it is it likes to curl back up a bit when not screwed down (since the piece i used was cut from the side of the drum), but that's no problem.  mother is working on sewing up a boss seat cover for me, so i should have that by tuesday and have the seat finished and mounted soon after!

(http://pic100.picturetrail.com/VOL1165/13336731/23780628/403581392.jpg)
Title: Re: '81 kz440: bobber --> cafe
Post by: tron97 on Aug 06, 2012, 12:57:41
Right on, I used abs for my seat pan as well.. It works great. Super easy to upholster, flexes a bit, and doesnt absorb moisture.
Title: Re: '81 kz440: bobber --> cafe
Post by: jdub on Aug 06, 2012, 13:02:47
I dug the baby blue color of the tank in the original post.

Other than a drum, if you can't get one, where do you get ABS like that for the seat?
Title: Re: '81 kz440: bobber --> cafe
Post by: tron97 on Aug 06, 2012, 15:33:15
http://www.amazon.com/H2O-Audio-Snow-Skate/dp/B0000AMA6N/ref=sr_1_3?ie=UTF8&qid=1344277951&sr=8-3&keywords=snowskate

I used something like that...fit my frame hoop perfect with a wee little trimming.
Title: Re: '81 kz440: bobber --> cafe
Post by: 7aliveatlast7 on Aug 06, 2012, 18:08:34
I dug the baby blue color of the tank in the original post.

Other than a drum, if you can't get one, where do you get ABS like that for the seat?

yeah, i was a fan of the blue as well, but i think i'm ready for a new direction.  nothing's in stone yet though!  as for the ABS, i have no idea!  i guess the snow skate thing works too, never thought of that. 
Title: Re: '81 kz440: bobber --> cafe
Post by: 7aliveatlast7 on Aug 13, 2012, 15:18:25
finally have a decent seat.  not my favorite thing ever, but it was home grown and practically free.  came to less than $8 for everything involved in it. 

(http://pic100.picturetrail.com/VOL1165/13336731/23780628/403650140.jpg)
Title: Re: '81 kz440: bobber --> cafe
Post by: jdub on Aug 13, 2012, 15:22:04
I like it.
Title: Re: '81 kz440: bobber --> cafe
Post by: CafeRacer650 on Aug 13, 2012, 15:45:37
It's lookin' mean!!
Title: Re: '81 kz440: bobber --> cafe
Post by: 7aliveatlast7 on Aug 13, 2012, 16:09:47
thanks guys!  forgot to mention i also scored a 50' roll of copper colored exhaust wrap on amazon for $10!  haven't seen it for less than 45-55, so i was very pleased with that deal to say the least.  reason for it being so cheap was that it was "used" but in "like new" condition.  i thought how the heck could you "use" exhaust wrap but still have it in "new" condition?  figured i'd chance it and see, and it turns out "used" meant that the packaging it came it had been opened, but the wrap was still in it's plastic wrapper inside haha. 
Title: Re: '81 kz440: bobber --> cafe
Post by: Shermanator86 on Aug 13, 2012, 16:27:11
Looking good man, best $8 seat I've ever seen
Title: Re: '81 kz440: bobber --> cafe
Post by: 7aliveatlast7 on Aug 17, 2012, 00:55:32
haha, yeah, not bad for the price!  at this point, i'm at a crossroads...i'm not sure whether to go with the dual straight pipes, or make a 2-1 collector and run the shorty reverse cone muffler i bought thinking i would want it for this build.  as of now, i'm leaning towards the muffler, but we'll see what happens!

here's a quick (and crappy) shot with the muffler mocked up on it.

(http://pic100.picturetrail.com/VOL1165/13336731/23780628/403677001.jpg)



or the straight pipes.

(http://pic100.picturetrail.com/VOL1165/13336731/23780628/403650140.jpg)
Title: Re: '81 kz440: bobber --> cafe
Post by: Shermanator86 on Aug 17, 2012, 03:37:16
I'm digging the 2 into 1, gives more of a finished look to it
Title: Re: '81 kz440: bobber --> cafe
Post by: M.B Co on Aug 17, 2012, 09:28:01
I dig the straights. Goes with the theme a little more. Love the build man, and that seat is rad.
Title: Re: '81 kz440: bobber --> cafe
Post by: JustinLonghorn on Aug 17, 2012, 09:57:10
I like the look of the straights, but the functionality of the muffler...hmmm.

Bike's looking great man.
Title: Re: '81 kz440: bobber --> cafe
Post by: 7aliveatlast7 on Aug 17, 2012, 12:09:34
I like the look of the straights, but the functionality of the muffler...hmmm.

Bike's looking great man.

that's EXACTLY my dilemma!!  i posted a pic a page or two back of some baffles that i picked up when i was still planning running straight pipes.  would it be wise to run them still if i went with the muffler?  i'm a newbie when it comes to exhaust stuff :/
Title: Re: '81 kz440: bobber --> cafe
Post by: Bobbed_out on Aug 17, 2012, 14:53:27
I would go with the straits...more of a bobber type style.
Title: Re: '81 kz440: bobber --> cafe
Post by: Erskine on Aug 27, 2012, 07:25:47
+1 for the straights.
Title: Re: '81 kz440: bobber --> cafe
Post by: CrescentSon on Aug 27, 2012, 09:34:16
Straights. No debate, not even close.
Title: Re: '81 kz440: bobber --> cafe
Post by: AnxiousCowboy on Sep 17, 2012, 21:24:22
How's this coming along? It looks good. What kinda shocks DID you have on the back? I need new ones. Wanna sell them and the remainder of your copper wrap to me? I'm planning on buying both of those things...
Title: Re: '81 kz440: bobber --> cafe
Post by: marla_do on Sep 18, 2012, 01:58:58
love this bike.

+1 for the straight pipes
Title: Re: '81 kz440: bobber --> cafe
Post by: 7aliveatlast7 on Sep 18, 2012, 11:35:43
How's this coming along? It looks good. What kinda shocks DID you have on the back? I need new ones. Wanna sell them and the remainder of your copper wrap to me? I'm planning on buying both of those things...

hey man, thanks for the compliment!  it's been at a stand still the last few weeks waiting for the exhaust to get finished.  it was supposed to get done last monday but i had to cancel on the guy that was finish welding it for me.  we re-scheduled for last night, but that ended up falling through again.  next monday we're giving it another shot, i'm reeeeally hoping it works out! 
i had progressive shocks on the rear, somewhere in the 11-12" range, but i can't remember for sure.  here's a pic from when they were on the bike...

(http://www.customfighters.com/forums/imagehosting/105384edaa3547916f.jpg)

i'll pm you about them and the copper wrap.
Title: Re: '81 kz440: bobber --> cafe
Post by: 7aliveatlast7 on Oct 09, 2012, 19:27:17
so i know it's been a long time since an update with this thing has happened, but that will *hopefully* be changing come tomorrow!  my friend who was TIG'ing up my exhaust got about 3/4 done, and has been busy ever since, so i've been stranded the past few months, not wanting to pay to have it done.  however, i just found a shop 25 mins away that will finish it up for $20!!  i'm trying not to be to excited, as plans have done nothing but fall through again and again with this exhaust, but i can't help it! 

after that's done, i just have to add oil, put in a battery, put my chain on, and hope she starts.  i may need a starter clutch, as that was going last time i rode her, but we'll see if i can't get her running without and just put one in over the winter. 
Title: Re: '81 kz440: bobber --> cafe
Post by: 7aliveatlast7 on Oct 11, 2012, 06:03:18
sneak peak! 

(http://pic100.picturetrail.com/VOL1165/13336731/23746917/404213471.jpg)

anyone in the eastern PA area should give absolute fabrication, llc. in whitehall, PA (near allentown) a call if they need any fabricating or welding of any material done.  the guys are awesome, are into bikes and cars, have unreal prices, and they are absolute pro's at what they do! 
Title: Re: '81 kz440: bobber --> cafe
Post by: 7aliveatlast7 on Oct 19, 2012, 11:25:06
just need to wrap them.  i originally wanted to use copper wrap, but decided against it and now want tan.  if anyone is in the market for a brand new roll of 2"x50' thermo tec copper colored exhaust wrap, pm me.

(http://pic100.picturetrail.com/VOL1165/13336731/23746917/404309206.jpg)
Title: Re: '81 kz440: bobber --> cafe
Post by: 7aliveatlast7 on Oct 20, 2012, 21:57:32
(http://pic100.picturetrail.com/VOL1165/13336731/23746917/404324040.jpg)
Title: Re: '81 kz440: bobber --> cafe
Post by: rattpunk on Oct 20, 2012, 22:05:39
Love that exhaust setup.  Looking great man.
Title: Re: '81 kz440: bobber --> cafe
Post by: CafeRacer650 on Oct 22, 2012, 10:38:50
It looks fantastic dude, keep it up!!
Title: Re: '81 kz440: bobber --> cafe
Post by: 7aliveatlast7 on Oct 27, 2012, 12:24:18
i have a problem.  i tried to start the bike this week and i'm getting NOTHING!  won't turn over, no lights, no nothing.  i'm certain i put all the wires back where they were supposed to go after i pulled/painted/reinstalled my engine, my battery is charged, and all my fuses are fine, none blown.  i can't understand why absolutely nothing works.  i don't know electrical systems very well, so if anyone could lead me through some steps to diagnose this problem, i would be eternally grateful!
Title: Re: '81 kz440: bobber --> cafe
Post by: 7aliveatlast7 on Oct 29, 2012, 01:55:43
got the bike running today!  i got my brief electrical scare sorted out and after a lot of tries, she finally kicked over!  thanks to those of you who offered help and suggestions.  here's a video, kinda dark in the garage tonight but at least you can hear the bike running.  we figured out the oil leak you can hear my wife and i talking about in the vid.  turns out i forgot to replace the crush washers at the banjo bolts on the oil feed line, so doing that should fix up the leaking.  i love the sound of the exhaust, super stoked on it!

http://www.youtube.com/watch?v=N5gAvlnU07w
Title: Re: '81 kz440: bobber --> cafe
Post by: JKN4 on Oct 29, 2012, 16:42:05
What was the electrical problem and how did you fix it??? I am stuck in the same problem right now. No power at all.
Title: Re: '81 kz440: bobber --> cafe
Post by: 7aliveatlast7 on Oct 30, 2012, 15:50:33
i found a ground wire that had come undone from somewhere.  i just connected it to the negative battery terminal and all is good now!  definitely get a multimeter.  that was suggested to me, but luckily i didn't so much as get it out of it's box before i noticed that ground wire hanging out. 
Title: Re: '81 kz440: bobber --> cafe
Post by: SoyBoySigh on Nov 10, 2012, 08:05:15
I LOVE that exhaust! Somebody's gotta start making 'em and selling 'em. Maybe all scrambler pipes for all sorts of bikes, it'd be a good business. Anyway, please post anything you find as to burn risks for passengers etc. I wanna do one up just like that, but the bike is for my teen daughter first of all, and she'll very likely have her "cycle bitch" on the back seat and all of that, so I just don't wanna burn anybody. So I'm thinking of heavy duty heat shields or maybe routing the pipes very differently, tough to say. I'd like to do a twin pipe thing, just over the engine cases, maybe then with a bash plate on the bottom. Going with both sixteen inch wheels, got a GT750J drum hub for it, Borrani 3x16" front rim for it - it looks cool no room for spokes ha ha, if it were a 10" or 12" tire you could just stick it on the drum ... which sounds even better than this wheel actually ha ha. But yeah, Maxi-scooter tires, low profile, 110/70 and 120-130/70 so even lower in the back end too, which means I really wanna clean up the lower sides to help with clearance etc. Maybe one pipe down the center, I dunno.... Ha anybody ever figured out how to do an oil cooler on these bikes? There's such a great place for one, between the down-tubes, a long vertical oil cooler. I'm sure people would say I don't need it, but I've actually had an old motor burn up over-heated on the high-way. I don't want that happening again. I can see the intake at the sump all of the Kawi bikes use a long tube to the oil pump intake. Maybe that can be adapted? Or maybe some kind of thing can be modded, like the oil filter cover etc. I wouldn't wanna take it off the line that goes to the head, but maybe there's something can be done to route it off the oil pump somehow. Oh, and the oil pumps, I wonder if there's a bigger bike's oil pump that would fit? Maybe a different part inside with some shimming, to put a bigger rotor inside the pump? I guess I should tear one apart, but I just thought I should look around for a tried and true solution from out there in the KZ world. I'm a DOHC Honda guy, even though I've had this bike for longer. It's just sat in storage, and I have always planned to fix it but put it off and put it off. Now I'm in a hurry. Ha ha. But, I've got two engines, and I'm not averse to buying a third for a good rebuild. Big ideas about a kick start on a 440, kick start only strip off some weight, etc etc etc....
Title: Re: '81 kz440: bobber --> cafe
Post by: SoyBoySigh on Nov 10, 2012, 08:37:30
ABS drum for seat pan is an awesome tip! Here I've gone with fibreglas time and time again. But hey, are you sure you don't mean POLYETHYLENE? If you DO mean ABS, you should be able to glue it with pipe cement from the hardware store. My DOHC Honda seat-pan I have made a replacement from Bondo as the original - it's DELRIN, which is Nylon with glass fibres in it. Nylon you can heat weld, but not with the glass strands, it creates weak spots where the strands don't go back in. I've tried it. But yeah, if you do indeed have ABS you should be able to heat it in the oven to get the curl out - actually that'd work better on the polyethylene, only they'll both smell that's for sure. I figure fibreglas might just work fine with the staples anyway, what with the complex shapes I wanna make. Still, you get top points for recycling, I just LOVE that kinda thing. It's just that ... 50 gal barrels are such a good thing for rain-water catchment, "grey-water" recycling into the garden, etc etc - I don't think I'll cut up any of my own. I was a really hard-core aquarium geek for a long time, import warehouse staff to gov't lab worker, I did a LOT of fish-geek stuff, and I was a hard-core gardener too - I just can't wrap my head around not hanging onto a good barrel. Oh, and if you're into Zombie Survivalism too, that's your water resovoir VERY important! I always wanted to plumb one in direct to my toilet, to fill up the tank with every flush, plumbed such that the fresh line water going through the barrel refreshes it. Then, in event of water supply failure, you've got a barrel - maybe barrelS - of fresh water, or pretty damned fresh, seeing as you flush often enough to recirculate and replace it. It could just go on the supply line straight out of the wall, then it would replace with ALL of the water going into your house. At which point, you could put several of 'em in line, due to the overall larger rate of replenishment. Put a couple good ones in a crawl space like that and hell, you could have that and your cases of baked beans, just hole up with your ammunition and sip away on your barrels of water - then there's no panic where you fill your tub and drink traces of shampoo and exfoliated skin, etc etc etc. Far better to have that already done, and to be able to stress about the PROPER things in event of an emergency. Fish tanks make a great water reserve, but without recirculation they can foul pretty quickly. Anyway, obviously I've just "outed" myself as a nut-job. But hell, I live in Mormon territory here in Southern Alberta. Living here as a kid, ALL of the kids I played with had huge truck sized stacks of cans in their basements -and being a really poor kid (no exaggeration, lived in a car briefly then moved into a house with fire damage and black walls, nothing but peaches and creme flavoured instant oatmeal for two weeks straight, etc etc) I think that's the one thing that gave me the impression that those friends came from wealthy families, 'cause they had FOOD. Ha ha ha. They all had guns too, that's what made me jealous, what with my hippie pacifist feminist matriarch at home I was lucky to get a sling-shot. Ha ha ha. Still, when everybody in your class ... I almost said neighborhood but the neighborhood was just like my place - when all of your classmates are from survivalist nut-job families it rubs off in strange ways. Or maybe it was their religious intolerance and conservative extremism that made me feel like boarding up the house and protecting it with a gun.... Whatever. Just don't wreck your barrels people! I'd give you top points if you could make it out of used drinking water bottles - but only if you didn't BUY the stupid things in the first place ha ha - maybe using a seat foam made up of chopped up kids' stuffie toys that were made from recycled pop bottles? I'm gonna use wheel-chair cushions, they make 'em out of the same blue gel as Dr Scholl's shoe insoles. Should feel good on the hiney. I also thought about silicone breast implants, or better still silicone BUTT implants. I mean, on my BIKE SEAT ha ha NOT on my BODY - I wanna go with the low profile slim-line seat and everything, but I want OEM seat covers - not neccessarily from the exact same bike - same make at least - but yeah, I also want the good cushioning. The yellow foam is old school. They don't make children's mattresses out of that stuff anymore. The nice thing about having a crappy old used one was that you could tear holes in it to make terrain for your plastic army men, trenches and shit. Yeah, anyway I've thought about roll up camping mattresses, yoga foam blocks, etc etc - but I think the gel stuff is the best idea so far. And they make auto seat cushions using knock-off versions of the same stuff. I bought some clearance items at Crappy Tire (oh if you don't live in Canada that means "Canadian Tire") with black waffle pattern gel, I'm gonna try 'em out on the seats, and if they work out great but I think I'll seek out some solid block type gel for wheel-chairs. What would be nice, in the summer, a zipper around the seat and you could slip in a pad from the freezer or fridge. In spring/falll - winter for you Southern folk, some kind barley neck bag thing that you could stick in the nuker. Conversely, just in case of opportunity to wire it into the bike down the road, it might be nice to put some kinda heater into the seat cushioning, built in. Yanno?

-S.
Title: Re: '81 kz440: bobber --> cafe
Post by: RedBullEnema on Nov 10, 2012, 15:14:21
(http://i1112.photobucket.com/albums/k491/RedBullEmena/WALL_OF_TEXT.jpg)

In other news...excellent work, the bike sounds great!
Title: Re: '81 kz440: bobber --> cafe
Post by: .Spindat. on Nov 10, 2012, 15:52:47
I am having such a difficult time wrapping my head around how your mono shock set up works, is that bracket the shock is attached to at the bottom attached to the swing arm? any close up pictures? curiosity is killing me


great work btw! its an amazing build
Title: Re: '81 kz440: bobber --> cafe
Post by: 7aliveatlast7 on Nov 10, 2012, 16:10:59
In other news...excellent work, the bike sounds great!

haha, thanks!  i looked at those prior two posts first thing this morning and they made my head hurt, haha.  hey, whatever picture you tried to post didn't show up, only saw a red "X."

I am having such a difficult time wrapping my head around how your mono shock set up works, is that bracket the shock is attached to at the bottom attached to the swing arm? any close up pictures? curiosity is killing me


great work btw! its an amazing build

i'll get you some pics!  you're just interested in how it attatches at the bottom, correct?  it's off a 2010 ninja 250ex, and it's got a couple dog bone linkages, but i'll try to snap a few shots of it for you.  i know what it's like to be curious and need answers, my nickname was curious george as a kid, haha :)  thanks to the props!
Title: Re: '81 kz440: bobber --> cafe
Post by: .Spindat. on Nov 10, 2012, 16:40:24
yeah exactly! it is the engineer in me haha
Title: Re: '81 kz440: bobber --> cafe
Post by: 7aliveatlast7 on Nov 12, 2012, 00:33:33
now i can see the pic, it made me laugh :)  i'm gonna get those pics for you soon .spindat.  got a lot done this weekend.  dropped to one rotor/caliper up front cause i didn't need all that stop power for a lil 440.  left side now looks pretty cool all opened up on the front wheel with no rotor.  fit a new tank, it looks awesome.  it's off an old xl350.  got my chain on, clutch cable back in place, clutch cover back on.  also got the rear brake caliper on, but it's gonna be some work figuring how to get my stock brake pedal to engage the master cylinder.  wish i could justify spending the money on some rearsets, ha.  i'll have pics up soon.  g'night!
Title: Re: '81 kz440: bobber --> cafe
Post by: 7aliveatlast7 on Nov 13, 2012, 20:42:12
so i bled my front brake today and have a slight problem.  i have a nice stiff lever pull, however, when i pull it, it does not spring back into place.  any ideas why that might be?  the calipers disengage when i let go of the lever, so it's not the pistons sticking or anything.  maybe a weak return spring in the lever?  any help is appreciated!

i just have to de-rust-ify the inside of my new tank and this thing will be ready to ride!  as long as no unforeseen problems arise, that is.  i tried the electrolysis method with a 10 amp charger, but can't seem to get any results.  i am sure my sacrificial anode is not touching the tank anywhere, so it's not grounding out.  however, after 24 hrs, it did not collect any rust!  do i need more sodium hydroxide?  i mixed one tablespoon with each gallon of water i put in the tank.  i'm stumped as to why it's not working. 
Title: Re: '81 kz440: bobber --> cafe
Post by: marla_do on Nov 15, 2012, 05:31:47
keep it up
Title: Re: '81 kz440: bobber --> cafe
Post by: 7aliveatlast7 on Nov 15, 2012, 17:27:54
new tank for this steed...

(http://pic100.picturetrail.com/VOL1165/13336731/23746917/404649275.jpg)

tried the 'ol handfuls of screws/nuts/bolts in the tank trick.  wrapped it in a blanket, threw it in the dryer with a few other thick blankets around it, and 45 mins later, it's looking a lot less rusty inside.  still some work to do, though. 
Title: Re: '81 kz440: bobber --> cafe
Post by: JustinLonghorn on Nov 15, 2012, 19:03:00
That tank looks the business. I can definitely dig it.
Title: Re: '81 kz440: bobber --> cafe
Post by: M.B Co on Nov 16, 2012, 18:25:31
Love this bike. Killer job man.
Title: Re: '81 kz440: bobber --> cafe
Post by: Big-D on Dec 04, 2012, 10:53:18
Ahhhhhhhhhhh this is KILLER!! This is the same exhaust I want for my KZ. I just havent gotten around to fabbing it up yet. What did you do with your battery?
Title: Re: '81 kz440: bobber --> cafe
Post by: CrescentSon on Dec 04, 2012, 11:58:25
How you gonna fill the gap in front of the seat?
Title: Re: '81 kz440: bobber --> cafe
Post by: crackerman on Dec 05, 2012, 11:07:01
Looking good. Diggin the tank. I like the exhaust but your going to burn you leg off unless you got nice heat shield. My scrambler pipes get nice and hot and they have a heat shield. Not a big deal, but you'd never want to wear shorts.
Title: Re: '81 kz440: bobber --> cafe
Post by: 7aliveatlast7 on Dec 05, 2012, 11:43:14
How you gonna fill the gap in front of the seat?
i don't know that im going to at all, at least for the time being.  i kinda like it with the gap.  i'm still toying with ideas though, so we'll see what happens with it.

Looking good. Diggin the tank. I like the exhaust but your going to burn you leg off unless you got nice heat shield. My scrambler pipes get nice and hot and they have a heat shield. Not a big deal, but you'd never want to wear shorts.

yes, heat shields are definitely going to be a must, haha.  i'm planning on making my own at some point this winter.

i usually only get to work on the bike for 3-4 hours each saturday, so work has been slow.  i welded a few bungs into my frame to mount the rear master cylinder, also welded up my rear brake pedal to work with where the MC is now mounted.  just have to fab up a short connecting rod between the pedal and the MC, then bleed it all and i'll have a rear disc brake!
Title: Re: '81 kz440: bobber --> cafe
Post by: .Spindat. on Dec 05, 2012, 17:08:04
spray foam will fill that gap just fine...haha
Title: Re: '81 kz440: bobber --> cafe
Post by: CrescentSon on Dec 06, 2012, 05:09:39
If you have any of the seat material, a separate pad wedged in there could look good. The gap just looks unfinished.
Title: Re: '81 kz440: bobber --> cafe
Post by: compoundcycles on Dec 09, 2012, 12:44:28
Your exhaust is awesome I really want something similar for my ride. As for the gap between the seat and the tank...consider doing something off the wall, like mounting your speedo there. You can just glance down if you really need to see how fast you're going. Then just keep the single tach up top for a cleaner look. Just a thought. I've been racking my brain for a cool place to relocate my speedo.

Awesome build. Keep it up.
Title: Re: '81 kz440: bobber --> cafe
Post by: 7aliveatlast7 on Dec 18, 2012, 18:16:38
haven't given much proof of progress yet, but here's a couple pics.  i've been working on cleaning up my wiring, and figured i better do it proper and make some sort of tray for my electronics and such.  here's what i came up with today...

(http://pic100.picturetrail.com/VOL1165/13336731/23746917/405043154.jpg)

just tacked up for now.  i have a little work left to do on it, but it's in and secured and i'm really happy with it so far.  i drilled and tapped 4 small holes in my subframe which is how the tray is secured to the bike.

i also took a pic of my recently finished rear disc brake setup.  i've had it all laying around for a while, but finally welded some bungs into the frame so i could mount the master cylinder.  i forgot to get a pic of the pedal, which i also had to modify a little, but you get the idea...

(http://pic100.picturetrail.com/VOL1165/13336731/23746917/405043153.jpg)
Title: Re: '81 kz440: brat cafe build
Post by: fodder on Dec 19, 2012, 23:17:32
I have joined just to ask about your monoshock setup. I am currently doing the same thing with a swing arm and shock from a ex500 as well as converting the rear to disc. Any pics or info tou could share would be great....
Title: Re: '81 kz440: brat cafe build
Post by: Mr. Sinister on Dec 20, 2012, 09:14:21
I have joined just to ask about your monoshock setup. I am currently doing the same thing with a swing arm and shock from a ex500 as well as converting the rear to disc. Any pics or info tou could share would be great....

THIS guy!!  ;D
Title: Re: '81 kz440: brat cafe build
Post by: fodder on Dec 20, 2012, 09:23:41
Damnit Bill!
 >:(
Title: Re: '81 kz440: brat cafe build
Post by: 7aliveatlast7 on Dec 20, 2012, 10:27:03
^^ haha, what's all that?  anyhow, i'd be happy to help with pics, but if you could let me know more specifically what you'd like to see, that would help me.  what kind of bike are you doing the swap on?
Title: Re: '81 kz440: brat cafe build
Post by: Mr. Sinister on Dec 20, 2012, 10:34:28
^^ haha, what's all that?  anyhow, i'd be happy to help with pics, but if you could let me know more specifically what you'd like to see, that would help me.  what kind of bike are you doing the swap on?

He's a good friend of mine. We built my bike in his barn, and are in the process of building his. I sent him a link to your thread, and told him he has to research his own bike!!  ;D

He's got an 80 KZ440, and we're trying to figure out how to mount the front of the monoshock arm. We were going to try and use the center stand mounts, but the geometry doesn't work. We have the swingarm fit, it just needed some grinding on the frame.
The upper shock mount should be cake, but I'd love to see pics of what you came up with!!
Title: Re: '81 kz440: brat cafe build
Post by: compoundcycles on Dec 20, 2012, 22:48:11
I'd love to see some closeups of your 2 into 1 collector and where the muffler joins. Really really nice work! I never hit you up about skinning my seat because I once I got the seat pan finished I couldn't wait to put it on so I tried it myself. Thanks again for the offer.
Title: Re: '81 kz440: brat cafe build
Post by: fodder on Dec 20, 2012, 22:53:00
Ditto on what Bill said.
Title: Re: '81 kz440: brat cafe build
Post by: diggerdanh on Dec 20, 2012, 23:36:17
How well did the EX250 swingarm fit? What types of things did you have to do to make it fit? Did you use the Ninja's pivot bolt or the KZ's? Thanks!
Title: Re: '81 kz440: brat cafe build
Post by: marla_do on Dec 21, 2012, 02:16:41
seat and tank looking good

love the tires
Title: Re: '81 kz440: brat cafe build
Post by: two-smoker on Dec 21, 2012, 03:44:51
I don't know what's involved on a KZ, but an EX250 swingarm will fit an XS650 frame if you grind 6mm off the pivot- 3mm on either side, and 6mm off the spacer as well. It even has the same pivot bolt diameter. I don't imagine the KZ is much different....
Title: Re: '81 kz440: brat cafe build
Post by: LeChu on Dec 21, 2012, 05:18:02
KZ looking great!, what year is the gsxr forks off of?? sorry if it was previously posted, skimmed through the posts and must of missed it. Thanks.
Title: Re: '81 kz440: brat cafe build
Post by: 7aliveatlast7 on Dec 21, 2012, 11:20:35
He's a good friend of mine. We built my bike in his barn, and are in the process of building his. I sent him a link to your thread, and told him he has to research his own bike!!  ;D

He's got an 80 KZ440, and we're trying to figure out how to mount the front of the monoshock arm. We were going to try and use the center stand mounts, but the geometry doesn't work. We have the swingarm fit, it just needed some grinding on the frame.
The upper shock mount should be cake, but I'd love to see pics of what you came up with!!
ha, cool to see friends helping each other out, sounds like you've got a good thing going!  I had the same thought of trying to use the centerstand mounts, but you're right, no can do there.  however, I cut those mounts off, made some longer tabs, and welded them to the same cross tube the centerstand mounts were on.  i'll pm you some pics to show you what it ended up like.
 
 
I'd love to see some closeups of your 2 into 1 collector and where the muffler joins. Really really nice work! I never hit you up about skinning my seat because I once I got the seat pan finished I couldn't wait to put it on so I tried it myself. Thanks again for the offer.
hey man, no worries about the seat, I actually meant to comment on your thread about how great it looked.  nice job!  and I will get you some pics of the 2-1 collector.  basically all I did was cut wedges out of a straight piece of 1.5" tube, put the wedges together to form two curves, then welded the curves together to form a 180* bend.  then I cut a 1.5" hole at the top of the 180 and welded in a short piece of tube to act as a sleeve for the muffler to slip over.  actually, I should stop saying "I" and making it sound like it was me who did all the work.  I simply cut and tacked it all together and had a friend TIG weld it up.
 
 
How well did the EX250 swingarm fit? What types of things did you have to do to make it fit? Did you use the Ninja's pivot bolt or the KZ's? Thanks!
the swingarm fit PERFECTLY!  I mean no cutting, no shaving, no nothing, it literally slid right into the 440 frame.  it was dumb luck, but the swingarms were exactly the same width at the pivot point.  I actually could not use the ninja pivot bolt though, as it was larger in diameter than the kz's.  so I just swapped the bearings and used the kz bolt.
 
 
KZ looking great!, what year is the gsxr forks off of?? sorry if it was previously posted, skimmed through the posts and must of missed it. Thanks.
they're off a 2007 gsxr 750.  try allballsracing.com, they have a fork compatibility chart that shows you every year/make/model of fork that will fit your bike.
Title: Re: '81 kz440: brat cafe build
Post by: Mr. Sinister on Dec 21, 2012, 11:25:32
ha, cool to see friends helping each other out, sounds like you've got a good thing going!  I had the same thought of trying to use the centerstand mounts, but you're right, no can do there.  however, I cut those mounts off, made some longer tabs, and welded them to the same cross tube the centerstand mounts were on.  i'll pm you some pics to show you what it ended up like.


Dig it, I'd appreciate that!!
That was our thoughts as well, using that same spot, but longer/lower tabs.
Title: Re: '81 kz440: brat cafe build
Post by: diggerdanh on Dec 21, 2012, 12:43:03
the swingarm fit PERFECTLY!  I mean no cutting, no shaving, no nothing, it literally slid right into the 440 frame.  it was dumb luck, but the swingarms were exactly the same width at the pivot point.  I actually could not use the ninja pivot bolt though, as it was larger in diameter than the kz's.  so I just swapped the bearings and used the kz bolt.

Cool, that's great news. I read on the KZ Twins forum about a guy using EX500 swingarm and he said that it would just slide into his KZ400 if he took one of the dust caps off the swingarm. Sounds like it was just a hair too wide for the frame without a little tweaking. He had said the same thing about the pivot bolt, the Ninja one was a little too big for the KZ400 frame. Awesome, good to know. Sounds like accounting for some manufacturing tolerances a few mm either way in the frame and in the swingarm then the EX250/EX500 swingarm should fit into a KZ400/440 using the KZ's pivot bolt and proper bearing. Thanks for the info.
Title: Re: '81 kz440: brat cafe build
Post by: LeChu on Dec 21, 2012, 18:34:05
thanks for the  info, and keep up the good work, cant wait to see the final result!
Title: Re: '81 kz440: brat cafe build
Post by: fodder on Dec 22, 2012, 19:14:35
?the ex500 swingarm we used slid in with just i bit of grinding on both sides. the tabs for the center stand were close... but yeah, longer is what we will need. id also like make them a little heavier and maybe a gusset? :-\ not sure yet.... how did you get the top mount done? could we see a pic of that? and basically its just make sure its vertical as far as the angle of the shock is concerned... never really messed with a mono shock before.

thanks for any help....
Title: Re: '81 kz440: brat cafe build
Post by: 7aliveatlast7 on Dec 23, 2012, 23:19:19
yeah, the angle is nearly vertical.  i went to a local dealership and found an ex500 in their showroom, then got down on the ground and took a bunch of pics and inspected how they come from the factory before i did any work installing it.  i think there's a pic of the final top mount somewhere in here, but i'll pm it to you so you don't have to scrounge for it.  let me know if you run into any problems and i'll do what i can to help.  sorry i don't have any tech specs for you or anything, i just kinda thought about it and looked at if for a long long time, then went and did what seemed like it would work best.  luckily, the hole in the swing arm that the shock goes through is pretty small, so it doesn't leave much room to set the the angle of the shock way off in any direction.
Title: Re: '81 kz440: brat cafe build
Post by: 7aliveatlast7 on Jan 04, 2013, 15:49:11
so i ran into a little problem that i think i've figured out, i just wanted to see if anyone from the online world had any knowledge to add.  i have every major thing ready to ride on this thing, and it was turning over and everything.  however, it was getting pretty weak trying to start it, so i hooked it up to my car while trying to start it.  didn't turn the car on, just hooked it to the battery for a little extra juice.  i went to start it, it cranked once, and now i'm getting nothing, it won't turn.  no blown fuses or disconnected wires (that i've found in my searches, at least), just won't turn over. 

that is until today when i gapped the two points on the starter solenoid.  when i do that, the bike turns over.  now from what i've read, by gapping it like that, i'm bypassing the solenoid and in essence running the positive battery terminal directly to the starter motor, which is turning fine.  does this mean my starter solenoid has gone bad, or is there something else amiss??
Title: Re: '81 kz440: brat cafe build
Post by: two-smoker on Jan 04, 2013, 17:03:24
Stands to reason you need a new solenoid.
Title: Re: '81 kz440: brat cafe build
Post by: 7aliveatlast7 on Jan 04, 2013, 22:02:18
yeah, just wanted to make certain before i get another.
Title: Re: '81 kz440: brat cafe build
Post by: J.Sharer on Jan 05, 2013, 03:26:58
what helmet is that in the 3rd picture down on your original post?? looks like it says moto J on it but i tried googling it and came up with nothing..

great work on the bike. i keep thinking about doing a similar fork swap and rear swing arm swap on my kz400 but i honestly love the old bike look. so its hard for me to decide.
Title: Re: '81 kz440: brat cafe build
Post by: 7aliveatlast7 on Jan 05, 2013, 10:53:26
my helmet is a bell moto 3.  and yeah, it's a tough choice as the old standard forks and dual springs definitely look fine.  i saved the forks and wheels off it, so i'll be able to use them on something else someday.
Title: Re: '81 kz440: brat cafe build
Post by: compoundcycles on Jan 08, 2013, 04:13:29
How are you joining your 2into1 collector to the headers. Is there a sleeve or something that is joining the pipes where you have the pipe brace mounted to the frame? Great looking ride you've got there.
Title: Re: '81 kz440: brat cafe build
Post by: LeChu on Jan 15, 2013, 02:35:39
Did the zx6r front rim bolt right up to the gsxr forks?? Or did you have to machine spacers??
Title: Re: '81 kz440: brat cafe build
Post by: 7aliveatlast7 on Jan 15, 2013, 10:59:01
Did the zx6r front rim bolt right up to the gsxr forks?? Or did you have to machine spacers??

no machining needed.  i just bought a gsxr axle and spacers off a 2007 model, and it all matched up perfectly.

on another note, a BIG thanks goes out to moderator Tim for helping me with my starter solenoid.  he had a brand spanking new one laying around that he graciously sent me for the price of shipping.  now i'm back in business and ready to get this thing running.  sorry for no pics lately.
Title: Re: '81 kz440: brat cafe build
Post by: 7aliveatlast7 on Jan 19, 2013, 12:32:19
SON OF A GUN!  I got the new starter solenoid in and it still won't work unless I gap it.  anyone have any ideas?  the solenoid is brand new, I don't know what the problem could be.  gonna spend the day checking my wiring I suppose...  ::)
Title: Re: '81 kz440: brat cafe build
Post by: 7aliveatlast7 on Feb 02, 2013, 13:54:51
well doggonit...when i ran into the problem above, first thing i checked were the fuses.  everything looked up to snuff, so i got crazy checking EVERYTHING in my electrical system to no avail.  then the other day a guy on kzrider tells me that the old glass tube fuses can seem fine, but fail internally due to vibrations and stuff.  so i figure whatever, it's worth a shot.  and boy was it, she's turning over now!  i'll be trying to get her started again this week and hopefully be riding her by next. 


 
Title: Re: '81 kz440: brat cafe build
Post by: DesmoBro on Feb 02, 2013, 14:18:28
glad i just read this ....i have tried 2 solenoids and neither worked none of them were new tho....before i spring for a new one i'm going to try a new fuse

Thanks My Man
Title: Re: '81 kz440: brat cafe build
Post by: 7aliveatlast7 on Feb 02, 2013, 14:40:32
sure thing man, hope it works! 
Title: Re: '81 kz440: brat cafe build
Post by: 7aliveatlast7 on Feb 08, 2013, 23:45:09
got the bike running the other day, so that's a good sign.  made up a fender and mounted it today.   

(http://pic100.picturetrail.com/VOL1165/13336731/23746917/405574728.jpg)

(http://pic100.picturetrail.com/VOL1165/13336731/23746917/405574727.jpg)
Title: Re: '81 kz440: brat cafe build
Post by: compoundcycles on Feb 09, 2013, 18:21:09
This is looking awesome. Keep it up. Those tires Kendas?
Title: Re: '81 kz440: brat cafe build
Post by: VonYinzer on Feb 09, 2013, 18:28:53
Very cool man. You should cut those glass fuses out of the equation. They suck... Replace them inline blade fuses. Cheap and simple upgrade.
Title: Re: '81 kz440: brat cafe build
Post by: diggerdanh on Feb 09, 2013, 22:56:56
Wow, looks fantastic!
Title: Re: '81 kz440: brat cafe build
Post by: 7aliveatlast7 on Feb 10, 2013, 02:01:54
This is looking awesome. Keep it up. Those tires Kendas?

one's a kenda k761 and the other is a shinko 705.  i think front and rear respectively.

Very cool man. You should cut those glass fuses out of the equation. They suck... Replace them inline blade fuses. Cheap and simple upgrade.

what a coincidence, i just got a kit in the mail today and got it all put in!  got the ATM style fuses.  i'm very happy with it.  it looks fresh (not that anyone will ever see it) and should be a lot more reliable.
Title: Re: '81 kz440: brat cafe build
Post by: 7aliveatlast7 on Feb 12, 2013, 17:08:24
so i was on the fence about the front fender.  i like the idea of it, but maybe not this execution per say.  plus, it was originally intended to be a rear fender.  so i mocked it up on the rear today.  gonna make another one for the front, but i'm not sure what to do with it.  run it high, dirt bike style?  closer to the wheel?  idk, i'm still up in the air about it.  but here's some pics with my ideas to finish up the back. 

(http://pic100.picturetrail.com/VOL1165/13336731/23746917/405628668.jpg)

(http://pic100.picturetrail.com/VOL1165/13336731/23746917/405628666.jpg)
Title: Re: '81 kz440: brat cafe build
Post by: compoundcycles on Feb 12, 2013, 18:14:37
Maybe shorten up the back fender a bit more? I quite enjoyed the front fender in the more dirtbike position. Ive been wanting try try a front fender that only extends behind the forks, not in front.

Title: Re: '81 kz440: brat cafe build
Post by: 7aliveatlast7 on Feb 12, 2013, 20:05:29
Maybe shorten up the back fender a bit more? I quite enjoyed the front fender in the more dirtbike position. Ive been wanting try try a front fender that only extends behind the forks, not in front.

agreed.  you can't tell in the pics, but there's a dotted line of where i want to cut it off at, haha.  that would be interesting for a front fender, i wonder if you'd get any spray...
Title: Re: '81 kz440: brat cafe build
Post by: diggerdanh on Feb 13, 2013, 00:38:24
It looks good with the rear fender. And I agree that a little less of it would be better!
Title: Re: '81 kz440: brat cafe build
Post by: 7aliveatlast7 on Feb 22, 2013, 17:35:38
started on a heat shield today.  little more filing and it should be good to go.  steel frame with perforated aluminum inner. 

(http://pic100.picturetrail.com/VOL1165/13336731/23746917/405754528.jpg)
Title: Re: '81 kz440: brat cafe build
Post by: compoundcycles on Feb 22, 2013, 18:09:20
Now thats classy. I like it.

Title: Re: '81 kz440: brat cafe build
Post by: Moban on Mar 06, 2013, 11:09:46
Love the stance of this thing.
Lookin mean.
Title: Re: '81 kz440: brat cafe build
Post by: spyra78 on Mar 13, 2013, 19:14:44
really cool bike!!

and that heat cover is pretty nice! Need something on mine. Going to make it tomorrow.. hopefully.
Title: Re: '81 kz440: brat cafe build
Post by: 7aliveatlast7 on Mar 13, 2013, 22:53:27
thanks!  i just mounted it yesterday and i'm pretty happy with it.  i'll have to get a pic of it and a few other updates i've made lately.
Title: Re: '81 kz440: brat cafe build
Post by: spyra78 on Mar 14, 2013, 08:03:05
Yeah man! put some updates here!

ps. i have posted some pics of my cone pipes as u wanted to know how its build...

http://www.dotheton.com/forum/index.php?topic=44492.new#new
Title: Re: '81 kz440: brat cafe build
Post by: 7aliveatlast7 on Jun 03, 2013, 00:59:34
been a long time, but the bike is "finished" for now.  just need to tune up the brakes and renew my registration.  gonna be a good summer!

http://www.youtube.com/watch?v=XgrxHxxJ6Uo
Title: Re: '81 kz440: brat cafe build
Post by: M.B Co on Jun 03, 2013, 09:56:29
Looking and sounding good. Great feeling isn't it.

Hopefully I get to feel it soon.
Title: Re: '81 kz440: brat cafe build
Post by: compoundcycles on Jun 10, 2013, 04:08:10
Nice work, your exhaust sounds so much quieter than mine. Very cool to see you on the road. I'm almost done as well.
Title: Re: '81 kz440: brat cafe build
Post by: 7aliveatlast7 on Jun 10, 2013, 11:19:42
great feeling indeed!  just waiting on my registration sticker to come in and i can start riding it everywhere.  and compound, i noticed that when i saw the vid of your bike running!  i was actually very surprised at how muffled the sound was when i first got it started.  any updates on yours, or just working out little kinks?
Title: Re: '81 kz440: brat cafe build
Post by: compoundcycles on Jun 11, 2013, 01:35:44
Yep, just tweaking the carbs and buttoning up the wiring. I got the title in the mail just yesterday! I shot some photos as soon as they're ready I'll update with a final post. Can't believe it's almost over...time for the next one.

Do you have any closeup pics of the leg guard all mounted up?
Title: Re: '81 kz440: brat cafe build
Post by: 7aliveatlast7 on Oct 06, 2013, 18:31:48
So I haven't posted in this thread for a long time, been too busy enjoying riding this old gal all summer :) had it at a few bike nights and got a ton of attention with it, but it made me realize I really needed to paint it. So I finally did! Still wanted the raw look without it rusting, and I love old school looking lettering, so this I what I went with...

(http://pic100.picturetrail.com/VOL1165/13336731/23746917/407727973.jpg)

(http://pic100.picturetrail.com/VOL1165/13336731/23746917/407727972.jpg)

(http://pic100.picturetrail.com/VOL1165/13336731/23746917/407727971.jpg)

(http://pic100.picturetrail.com/VOL1165/13336731/23746917/407727969.jpg)

It's actually a light cream color at the top of the letters, not a dull yellow like it looks in the pics. I finished it all off (along with the front fender) with 2k clear coat. First time using it, and am is it awesome. Made a believer outta me. Easy to use, dries fast and to a super smooth finish. Will definitely be using it again in the future.
Title: Re: '81 kz440: brat cafe build
Post by: Shermanator86 on Oct 09, 2013, 15:31:44
Awesome man, like the paint.
Title: Re: '81 kz440: brat cafe build
Post by: M.B Co on Oct 09, 2013, 16:24:37
Do you have a vid of how the exhaust sounds?
Title: Re: '81 kz440: brat cafe build
Post by: 7aliveatlast7 on Oct 09, 2013, 18:25:22
Thanks shermanator! And m.b.co, I do, it's posted one page back. You were actually the first one to comment on it and how you liked the sound haha.
Title: Re: '81 kz440: brat cafe build
Post by: M.B Co on Oct 09, 2013, 18:40:28
Thanks shermanator! And m.b.co, I do, it's posted one page back. You were actually the first one to comment on it and how you liked the sound haha.

Thats right, I thought I did...ha. It's been a long day at work.
Title: Re: '81 kz440: brat cafe build
Post by: 7aliveatlast7 on Oct 11, 2013, 11:50:20
haha, no worries!  we've all had those :)
Title: Re: '81 kz440: brat cafe build
Post by: treitz on Mar 24, 2014, 19:29:28
Love this bike! I'd love a set of pipes like that on my KZ400, but I do not have the skill-set to build them at this point in time. Maybe down the road.

Really good looking bike though!
Title: Re: '81 kz440: brat cafe build
Post by: 7aliveatlast7 on Mar 31, 2014, 22:26:10
Love this bike! I'd love a set of pipes like that on my KZ400, but I do not have the skill-set to build them at this point in time. Maybe down the road.

Really good looking bike though!

Hey man, thanks for the comment! To be honest, I really didn't have the skills either, just an idea of what I wanted and a little flux core mig welder that I learned to use as I went haha. It's completely within reach for any one!
Title: Re: '81 kz440: brat cafe build
Post by: LDSchmidt on May 15, 2014, 16:30:29
Amazing Bike! I went through your thread here and on CF. It has evolved to very similar to what I want mine to look like. Just wondering if you know if the zx6r front wheel would work with a 96 gsxr front end. I have the opportunity to buy one on the cheap but have no interest in having the 3 post rims of the old gsxr.
Title: Re: '81 kz440: brat cafe build
Post by: 7aliveatlast7 on May 16, 2014, 11:59:08
Amazing Bike! I went through your thread here and on CF. It has evolved to very similar to what I want mine to look like. Just wondering if you know if the zx6r front wheel would work with a 96 gsxr front end. I have the opportunity to buy one on the cheap but have no interest in having the 3 post rims of the old gsxr.

thanks for the comment!  i honestly have no idea if it would fit, i didn't even know if it would fit in my forks.  i just tried it and it happened to be perfect.  you may be able to find a chart online somewhere specifying how far the fork legs are set apart on each model.  or i can take a measurement on my zx6 wheel width and pass it on to you to see if it'll fit between your forks.
Title: Re: '81 kz440: brat cafe build
Post by: predawn sky on Aug 10, 2014, 13:49:32
i'm new here from customfighters.com.  my '81 kz440 project is well underway, but all the work done thus far has been on that site.  however, i grabbed some progress pics off there to make somewhat of a timeline for you all so you can see what i've been up to with this thing for the last year and a half!

this is how i bought it, as a "cool idea but pretty ugly" bobber...

(http://pic100.picturetrail.com/VOL1165/13336731/23780628/398123026.jpg)

beauty is in the eye of the beholder or builder
Title: Re: '81 kz440: brat cafe build
Post by: woodgeek on Nov 07, 2014, 21:55:36
How long is the EX250 swingarm, compared to the stock KZ swingarm?
Title: Re: '81 kz440: brat cafe build
Post by: 7aliveatlast7 on Nov 08, 2014, 09:00:56
It was a bit longer, but I sold the bike in August so I can't measure for you. Sorry :(
Title: Re: '81 kz440: brat cafe build
Post by: danker16 on Nov 08, 2014, 09:31:00
It was a bit longer, but I sold the bike in August so I can't measure for you. Sorry :(
I loved this bike, how come you ended up selling it
Title: Re: '81 kz440: brat cafe build
Post by: 7aliveatlast7 on Nov 08, 2014, 12:48:01
I loved this bike, how come you ended up selling it

I did too, and I often wonder the same thing haha. But that was the plan all along, to fix it up and sell it so I could move on to bigger and better things. I learned a lot during the process of building that thing, and I fully plan on getting another kz someday. They are great little bikes.