KZ400 "Dirty Bird" Cafe (Winter mods)

[Swapmeet Louie]

Re: 79 KZ400 Cafe (Project #2)

Are they coming out of a little cover on the side of the head? if so they are your ignition trigger wires/points wires depending on your application.


I think? haha

I dont own a kz, but just going by parallel twin common design.

If they are coming from the case/ top of a side cover they will most likely be stator/ alternator wires

 

[treitz]

Re: 79 KZ400 Cafe (Project #2)

Sorry this photo sucks but you can see the wire I am talking about.

The cover is being held on by one stripped bolt. Looks like the previous own got lazy and sort of bent the cover to get the chain off because he couldn't get the bolt out.

 

[Ethanol]

Re: 79 KZ400 Cafe (Project #2)

Yeah your alternator/dynamo is under there (along with some other important stuff). There should be a couple of heavy wires (cloth wrapped) coming out of that side. They will go to your regulator/rectifier and ground and maybe one to the battery? I forget.

This page has tons of info: http://www.kz400.com/WorkshopManFrameset-5.html

Also, if that cover is stuck a few gentle blows with a rubber mallet should coerce it off.

Ah, didn't read the part about the bolt. Drill it! It's a bitch but it'll work.

 

[Koestum]

Re: 79 KZ400 Cafe (Project #2)

The cover is being held on by one stripped bolt. Looks like the previous own got lazy and sort of bent the cover to get the chain off because he couldn't get the bolt out.

You can get the cover off.

Use a drill bit just a little bigger than the diameter of the threaded portion and drill the center of the screw head carefully until the screw head separates from the threaded portion. Then you can remove the cover and use vise grips to remove the threaded portion or leave it in as "locater".

 

[my94f2]

Re: 79 KZ400 Cafe (Project #2)

yeah drill the bolt out. but make sure its not binding on the gear selector shaft. every kawasaki i have owned or worked on seems to bind on the shaft. soak it. then dead blow it carefully

 

[treitz]

Re: 79 KZ400 Cafe (Project #2)

Yeah I am not too worried about the bolt. I had the same problem with my CL and got the covers off thanks to some drilling, grinding and pounding.

 

[treitz]

Re: 79 KZ400 Cafe (Project #2)

Yeah your alternator/dynamo is under there (along with some other important stuff). There should be a couple of heavy wires (cloth wrapped) coming out of that side. They will go to your regulator/rectifier and ground and maybe one to the battery? I forget.

This page has tons of info: http://www.kz400.com/WorkshopManFrameset-5.html

Also, if that cover is stuck a few gentle blows with a rubber mallet should coerce it off.

Ah, didn't read the part about the bolt. Drill it! It's a bitch but it'll work.

I have checked out that site. Tons of information!

I guess I will worry about the wires later. I have a lot of work to do before I start rewiring.

 

[Ethanol]

Re: 79 KZ400 Cafe (Project #2)

Hit me up when you get to that bit and I'll help you through it!

 

[treitz]

Re: 79 KZ400 Cafe (Project #2)

Hit me up when you get to that bit and I'll help you through it!

Will do!

I really appreciate everyones willingness to help on this site. I have been on so many forums where people are ass holes that it is refreshing to find one where people aren't!

Will continue to post photo's as this project progresses. Should be working on it a lot next week once the holidays are over and such.

 

[Ethanol]

Re: 79 KZ400 Cafe (Project #2)

Our motto should be "Will work for pics!"

We love us some pictures.

 

[treitz]

Re: 79 KZ400 Cafe (Project #2)

Our motto should be "Will work for pics!"

We love us some pictures.

Don't worry. I'll do my best to keep the pics coming.

Once I start getting more done I'll enlist the help of my wife and her fancy camera so the pictures are better.

 

[treitz]

Re: 79 KZ400 Cafe (Project #2)

Wow I can't believe this never crossed my mind. I work at a sign shop and have scrap aluminum laying around everywhere. I grabbed two pieces to try and make a couple seat pans out of.

The narrower blank is thicker so it will probably hold form better while the wider sheet is a bit thinner and tends to flex back to straight quickly.

We will see what happens when I get home and test fit them.

 

[treitz]

Re: 79 KZ400 Cafe (Project #2)

Well... Since the rear fender comes up above the frame I might have to get more creative than I thought. I was hoping to I could make the pan straight and flat, like I can on the CL, and create a seat like you see in the first image below.

The tabs from the stock seat are also going to be a issue. I know I could cut them off, but I don't want to because the single seat uses them. Opinions??

Issue #1

Issue #2

Second: I got the cover off so you can now see the wires I was talking about. Some random parts fell out too...

Random Parts:

Once I get the manual for this bike I should be asking way fewer questions.

 

[66replica]

Re: 79 KZ400 Cafe (Project #2)

Are you going to keep the seat that came with it or make a new one? If you're making a new one, cut that brace off and weld in a piece to make it flat. That also solves the seat tab issue, just cut 'em off. You'd also loose the rear fender but if it's like a CB the inner rear fender is a separate piece and you can keep it.

 

[treitz]

Re: 79 KZ400 Cafe (Project #2)

That's the problem, it's not like the CB. The fender connects to that brace. If I cut the brace off, I won't be able to mount the fender.

I'd like to be able to switch between the two seats if I can... but if that's not possible I will have to decide between the two and cut the tabs off if I choose the two-up approach.

 

[66replica]

Re: 79 KZ400 Cafe (Project #2)

Random pieces are clutch lever and clutch ball retainer

 

[treitz]

Re: 79 KZ400 Cafe (Project #2)

Random pieces are clutch lever and clutch ball retainer

That's what I thought.

 

[treitz]

Re: 79 KZ400 Cafe (Project #2)

Chances are I'll use the seat that came on it. I just thought it would be cool to be able to switch between the two seats if it wasn't too complicated.

Maybe I'll just need to find another stock seat, jack the tabs from it and make the two up attach in the same fashion.

 

[treitz]

Re: 79 KZ400 Cafe (Project #2)

This shows how the fender attaches...

I think I could arch the seat pan from the left side to the right side, but there wouldn't be much room for padding.

 

[treitz]

Re: 79 KZ400 Cafe (Project #2)

My new goal is to find this seat:

I would modify it slightly so it wouldn't be quite so big a bulky, but really I just want to be able to throw it on when I need two seats. So I don't care THAT much how it looks. This way the mounting would all be the same and it wouldn't require any modifications that would mess with the use of the cafe seat.