Danny's KZ200 cafe project

[danny_750]

Alright,  I've finally decided to post my Cafe build! This is my first motorcycle project, I have never owned a motorcycle and still don't have a motorcycle license but I pulled the trigger and bought a cafe style bike (79' kz200) from Craigslist. I have a small amount of tools and a big desire to make a sweet cafe. I've been working on the bike for the last month or so, she's almost complete,  here she is! (sorry for the grainy cell phone photos)


Finally in my possession!











Bought the bike with non working front brake....still need to buy a new one.











My first task, new clip ons, lowered gauges, new head light brackets.











Next I started gutting and cutting off all unnecessary tabs and brackets











New Dime City shorty exhaust mocked up








Seat from Airtech (duc75) mocked up








Seat and primed tank








Rear Sets














Battery holder





Engine Painted





Ignition mounted under tank








Bondoed couple dings in gauges





Painted Frame



Putting things back together






Painted exhaust white and plan to wrap in black exhaust wrap





I ran into a problem with the rear brake, exhaust and kickstand all hitting each other, my solution... adjusted angle of exhaust, mounted kickstand spring to inside of kickstand. reused brake springs and brake indicator.








Paint!

















Rear section complete







Thats it for now. I still have of a bunch of things to do but its coming along.

[danny_750]

paints dry!

[VonYinzer]

Well damn... You done eff around, do ya? Did you weld that muffler to the head pipe?

[danny_750]

Yes, I ran into clearance issues with the muffler and rear brake, had to lower the muffler to that awful angle to get the rear brake to work without rubbing. It looks terrible I know, I'm thinking about taking it in to an exhaust shop to reroute the exhaust up higher, honda scrambler style.

[danny_750]

More pictures!

[Selloutlabel]

awesome build man, i just picked up a kz200 in pieces from craigslist. i'll be doing something similar, good work on your first bike!!

[danny_750]

Update! Nearly complete!



Recently added the exhaust wrap, homemade seat, rear turn signals. The foam under my homemade seat is a little larger then I originally wanted but I'm hoping my fat ass and lots of fall riding  will lower the height.





Also tried making a white seat...bad idea. Using a sewing machine is a lot harder then I thought. The black Seat looks way better!


I need to re paint the gas tank. Theres a slight orange/red tint in the paint, poor tarp usage on my part, need to try to be more patient.


Still having trouble finding a front mechanical brake. If any one can help (finding a working brake or rebuilding advice) my parents will thank you come test day!


Finished photos coming soon!

[scott s]

 Very cool! I built its big brother last year (KZ250). You're lucky...I had to start with the "chopper" style frame and cut it up a LOT to get the cafe' look.

[danny_750]

Thanks! Whats the fastest speed you've done with your 250? I'm worried my little 200 wont be able to 'do the ton'.

[DP9]

nice build man.  clean, simple and I love the engine color.

[scott s]

Thanks! Whats the fastest speed you've done with your 250? I'm worried my little 200 wont be able to 'do the ton'.

 I've had it up close to 80 on a long stretch of road. It might break 85 going down hill! I really doubt that you'll be able to hit the ton with it.

[danny_750]

Its Alive!





Got her running last night, but realized the clutch wasn't engaging, it would die when I put it in gear. Heres a quick video of me starting her up and a couple revs, the battery was dead so I had a trickle charger on it.

[Penguins_48]

Thanks! Whats the fastest speed you've done with your 250? I'm worried my little 200 wont be able to 'do the ton'.

Danny,
Im building a kz200 as well. Ditch that caliper. They don't make rebuild parts. You may be able to graft a hydraulic from a newer bike or swap a 250 front end on there. Im working on something and if it works, ill give you details. 

[Erskine]

Nice proportions going on Looks great.