KZ 400 (slow) Build Thread

[Tsfc]

Hello to All. I have never signed up on any forum before. Long time lurker of do the ton here.. But this is the first post I have made...on any forum for that matter. This forum seems full of very helpful and knowledgable enthusiasts. I figured I should try participating as I can really only benefit from the plethora of information forum members here possess!

The unlucky candidate?? A KZ400. Yes, it is a smaller bike, but fun little boppers for around town.

The bike is currently in storage as I clear my condo living room out (I have a very understanding and easy going lady). Pictures will follow once the bike is here sometime next week. Build date on the neck states 1/79. Instead of moving tools from family home here, I sniped a brand new 207pc mech set sae/metric for a hundred bones. Good enough for the job.

I have a few plans for the bike, but nothing set in stone yet of course. Please, fellow members feel free to weigh in and provide your valuable insight. I would rather make plans during disassembly so I can get a much better feel of the frame and body lines, stance etc as it is stripped down. This will probably dictate my goals with the bike. Anyway, here are some general thoughts I have for the build:

- detab the frame, grind it down, weld in a battery/electronics box under the seat
- rear loop, slightly upswept angle for the seat to follow the form of
- powder coat the frame with a semi gloss brown, with a semi gloss clear coat over top. I would like some textured appearance to the frame. Think dark chocolate..then a bit lighter.
-powder coat the tank in a cream colour with high gloss clear coat
- ignition and electric start button (if retained) relocated under the seat somewhere.
- new rear sets
- digital gauge
- upgraded brake lines and mcyl
- mikuni carbs with new throttle cable and filters deleting the stock air box
- tomoselli clip one or trackers
- ikon rear shocks and fork springs
- undecided with engine. She was running when put away and started up right away every time but regardless will receive top end work and a serious polish. Possibly a full rebuild.
- rear disc conversion? Not needed, could be cool
- 2 into 1 exhaust
- new rubber, grips and the usual rigmarole

Any advice and suggestions are welcomed and I look forward to them !

Pictures to follow.

Thanks for checking out the post.

 

[chris27989]

sounds good.. looking forward to some picture.
Colour scheme sounds interesting and exciting

 

[Tsfc]

In mind at the moment for the tank, matte navy blue and cream

 

[Tsfc]

]This is the only photo I currently have of it (ipad screenshot) from the day it was put in storage recently. It currently has a god awful rattle can paint job from the previous owner... Matters not, out with the old and in with the new.

 

[chris27989]

I have the same problem with my build someone thought it would be a good idea to rattle can the bike and not make a good job of it!

 

[Tsfc]

It sounds as though the PO did a fine job of sourcing a decent bike though, as the engine did not need much to start after a sea foam or similar.

He decided to move on from it due to a leaky carb :s

Anyway, he rattle canned the tank, so fugly, and out some bent snowmobile bars on it. In his defence, he was at least a very nice guy. He mounted some lights too but nothing worked.. It ran, that is about it. The brakes are not in working condition either

 

[Tsfc]

Ripped by storage on the way home so I could snap a few quick photos, give you fine folks an idea of what I am working with.


It is the one in the middle, kept warm by friends and future projects. yanked it out for a second to take a few more.

 

[Tsfc]

I am really sorry, they posted sideways as you can see.

 

[Tsfc]

Here are a few more shots

 

[Tsfc]

FFS!! Sideways photos! Damn it.

Anyway, here are a few others waiting their turn patiently

 

[Tsfc]

And the cleared out living room on a third floor condo.. Was not kidding! Very good woman at home letting me do it haha.

Tool set and empty water bottle ( chew cup spitter ) and the lady cut up old jeans for me to use as rags. She gold!

 

[Nebr_Rex]

Do you plan to ride it or look at it?
If out plan on riding work on suspension and brakes.
Modified forks and better rear shocks help on the bumps.
Dual front disc can be done with the right parts.
Rear disc would take some serious modifications.
Clean and grease the swing arm pivot.
Replace the steering stem bearings with rollers.
As for the engine, a proper tuned up will deliver enough
performance for most riders. If you need more p.m. me.


.

Hello to All. I have never signed up on any forum before. Long time lurker of do the ton here.. But this is the first post I have made...on any forum for that matter. This forum seems full of very helpful and knowledgable enthusiasts. I figured I should try participating as I can really only benefit from the plethora of information forum members here possess!

The unlucky candidate?? A KZ400. Yes, it is a smaller bike, but fun little boppers for around town.

The bike is currently in storage as I clear my condo living room out (I have a very understanding and easy going lady). Pictures will follow once the bike is here sometime next week. Build date on the neck states 1/79. Instead of moving tools from family home here, I sniped a brand new 207pc mech set sae/metric for a hundred bones. Good enough for the job.

I have a few plans for the bike, but nothing set in stone yet of course. Please, fellow members feel free to weigh in and provide your valuable insight. I would rather make plans during disassembly so I can get a much better feel of the frame and body lines, stance etc as it is stripped down. This will probably dictate my goals with the bike. Anyway, here are some general thoughts I have for the build:

- detab the frame, grind it down, weld in a battery/electronics box under the seat
- rear loop, slightly upswept angle for the seat to follow the form of
- powder coat the frame with a semi gloss brown, with a semi gloss clear coat over top. I would like some textured appearance to the frame. Think dark chocolate..then a bit lighter.
-powder coat the tank in a cream colour with high gloss clear coat
- ignition and electric start button (if retained) relocated under the seat somewhere.
- new rear sets
- digital gauge
- upgraded brake lines and mcyl
- mikuni carbs with new throttle cable and filters deleting the stock air box
- tomoselli clip one or trackers
- ikon rear shocks and fork springs
- undecided with engine. She was running when put away and started up right away every time but regardless will receive top end work and a serious polish. Possibly a full rebuild.
- rear disc conversion? Not needed, could be cool
- 2 into 1 exhaust
- new rubber, grips and the usual rigmarole

Any advice and suggestions are welcomed and I look forward to them !

Pictures to follow.

Thanks for checking out the post.

 

[Tsfc]

Do you plan to ride it or look at it?
If out plan on riding work on suspension and brakes.
Modified forks and better rear shocks help on the bumps.
Dual front disc can be done with the right parts.
Rear disc would take some serious modifications.
Clean and grease the swing arm pivot.
Replace the steering stem bearings with rollers.
As for the engine, a proper tuned up will deliver enough
performance for most riders. If you need more p.m. me.


.

HeyNebr_Rex! Thank you for checking out the post and for giving your valuable advice.

as mentioned in my first post (which was poorly thought out and in the style of word-vomit) I do plan on upgrading the brakes and suspension. They are my primary concerns for the build, even though it may not sound so in the post quoted.

I have made note of your excellent suggested and look forward to hearing from you more over the course of urge build. Thanks !

 

[M.B Co]

I think I broke my neck looking at the pictures. Looks like a clean candidate for a build.

 

[Tsfc]

I think I broke my neck looking at the pictures. Looks like a clean candidate for a build.

I am really sorry about that buddy, I will get a handle on the sideways photos as the build posts increase hahah

I am itching to start disassembly but at this rate it will be a few days before I can move it here. It will come up in the elevator haha. Still have to get a stool and tarp and a few things for fluid drainage anyhows so I will try and use the time wisely!

 

[Tsfc]

I am trying to meet up with a local guy to have a look at his similar era kz650 tanks. They will likely fit on this frame, although I imagine I will lose an inch on the seat pan..

That Is fine with me though! If I can snag one I will get a bit more range out of that slightly larger tank and It should not look badly out of proportion if I am careful... I may do away with the original plan of a slightly upswept rear loop if it does look off, and keep the loop perfectly straight out. Hopefully that way the perception of length will make sure the tank won't look too out of place from side views.

If anyone has some other tank suggestions...

Cheers to all, any suggestions are appreciated.

 

[Tsfc]

Having some issues with my 3rd gen 4runnee today, (vibrating drivetrain, worse at low Rpm) so will probably check code and clean the throttle body and idle air control.

Will likely have the bike here early next week, stay tuned.

 

[Nebr_Rex]

You will need KZ440 forks like what is pictured.
Use your fork tubes, 440s are longer.
Any early set of KZ caliper will work.
Only machine work required is to drill and tap the right side of the hub.
This should be done by a machine shop.

.

 

[Tsfc]

You will need KZ440 forks like what is pictured.
Use your fork tubes, 440s are longer.
Any early set of KZ caliper will work.
Only machine work required is to drill and tap the right side of the hub.
This should be done by a machine shop.

.

You're the man, Mr. _Rex. I am currently on the hunt for kz650 bits, hopefully the dude I am going to see for the tank has a set of kz440 forks as well. Sounded like he had a good size lot of Kawi parts. Really appreciate the heads up!

 

[fury413rb]

I have a set of good looking polished Kz650 forks if you are interested.