my cafe racer projects kz400 uk lots of pics ******************************

[manchestermichael]

this is my first post and my first road bike to tinker with as i am most used to mx bikes but i am having fun with it i am from manchester 24 yeas old and am building my bike in my 3rd floorone bed flat hahaha witch i all ready have 4 mx bikes in my gf is not happy so its going to be a slow one to build been sniffing this site for to long so ill post up some pics of where i am at any help would be gr8 thanks got the bike for £40 pounds of ebay and was very happy when i got it home with a long overhall in my head best bits i could see are new ish tires thats it i am not planing on spending lots keep every thing cheap so this is it when i got it carbs stuck rust rust brakes stuck and about 5 paint jobs with 3 of them being paint brushed on

then i tore it apart

after about 7 hours trying to sort the carbs out and lost of cleaner

befor

after

then i sorted the wheels to my surprise new bearings new pads the wheels where rusted to hell so spent 5 hours with wire wheel and rust remover and the treated and primed and glosed black still needs clear to go on but looks good was going to respoke but bills needs paying so went for the cheap.. cut all frame bits off peg mounts sidepanel ect ect was planing to get a new tank so i am messing about with the old one which was full of filler bashed out the sides will refill and see how it gos but am looking for a nice long cafe tank will be making my own seat out of fiber glass and polished the motor up witch i dont no if it runs but has good compresion polished brake hubs forks and made a seat base got some clip ons will chop of the old bar mounts from the yoke and make flat and chop of the brake y thing will prob make custon carbon fiber clock holder or go with and digi one pod filters kick only no bat and maby race numbers for a daylight mot only

next get the motor in and try and get it runing will post more along the way thanks lots more photos if need

 

[manchestermichael]

not much to update really as xmas has been a no go for working on bikes but i did get time to take starter cover off witch was not an easy job and looked onehell of a mess inside water had got in it looked like . but there should be no oil in there right???? .. so took the starter motor out and chucked it .kick only all so ground of all the tabs on the frame propley and just chucked the motor back in for now how do i test the coils ?? i no to check for a spark but is there a way to huck up a tester to check and what power reading thay should show if ???even??? thats the way to do it . ?

all so made a quick test seat hump mold and anouther question with me bashing out the sides for the knees in the tank i have just figerd out my petcock wont fit in any more but will fit fine if i take the long brass straw off will this be ok with it off or cut down i dont see why not but you guys should no .?
anouther reason for the build going slow is a birthday prezzey to my self anouther project

i just could not pass it up for the price 30 quid honda cj250 with new shocks new lights new tires zorsts and box full of carbs and lots more he said he did not no anything about bikes but tryed to make this on look like on he saw on the internet olord what a mess but he never had it started but has good free motor i think but really shitty cafe attempet the guy i got it from paint brushed every thing :yikes red rims with house paint rusted frame painted over brushed red every thing els painted black and a really bad diy a seat hump with some sort of motocross seat. tank has 1000 dents all over it looks really bad looks like a 3 year old kid has gone to town with a paint brush but the photos make it look ok ish :? but hell it was 30 quid haha will post some pics of it in bikes forum index i no its no kz but the cafe bug has bit me thanks for the help

 

[zixxerboy]

Dude that bike had great patina ... and now it's gone. How sad

The brass straw is where your petcock draws from before reserve. Cut it off and you no longer have a reserve. No big deal really.

 

[troybilt]

Bike is looking much better already! Great job! You've taken a piece of shit that nobody wanted and are turning it into something to be proud of!

 

[HerrDeacon]

The before and after pics on this one are going to be incredible, going to be interesting to watch.

Carbs look great now, nice work.

 

[rawfish]

what bars are you running?

 

[manchestermichael]

i am runing race designs clip ons that i got for a steel on ebay bran new for 10 quid posted but thay dont seem to be that strong so might change them just working on geting the top yoke sorted bar mounts off clock mounts off all so got a set of mito upside down forks for cheap so will give tham a try so will be needing new clip ons anyway if i can get them to fit ok

 

[manchestermichael]

stared to open the motor clean up and checking

 

[Flugtechnik]

Your head looks happy to be clean!

 

[valvesprung]

Your head looks happy to be clean!

;D awesome...

 

[CaTacl1sm]

pics of the mario sleeve plz?

 

[manchestermichael]

not really a mario theam just littel bits chucked in done by my self ill dig a pic up if i can

 

[manchestermichael]

so got bord drilled my drive cover went a bit o t t just need to clean the holes and polish
outher small bits sorted like head light ears choped ect
about to give the frame a lick of paint just wateing on the motor and small bits to come

 

[boomshakalaka]

what did you use to clean the head? Im scared to wire wheel the mating surface, but the gasket is so stuck on there, and I am not happy with the results using a razorblade scraper so far. I am going to have access to a mediablaster (aluminum oxide media) but Im scared to use this on the mating surface as well. God I hate these 35 year old gaskets..

 

[manchestermichael]

i used a brass wire wheel and it worked fine just dont go to hard with it there is a prouct you can get i think its called goooff or something like that that just takes it off but really the brass wheel worked grate and was easy on the gasket surface just dont use a steel wheel and dont blast them with anything harsh

 

[manchestermichael]

any ideas on how to get the bleed nipple out that snapped off and the brake bolt thats stuck and rounded its been in wd40 for a week and i tryed heat will i have to drill them if so how? any tips thanks

 

[slushie07]

get a set of screw bolt extractors from your local hardware store, even cheap ones if used well can work pretty well

 

[boomshakalaka]

ok, Ill look into a brass wheel. I think I might have some for my dremel actually. And Ill try goof off or whatever, Ive used it before for other stuff, but never for this. I bought some gasket remover stuff but it really hasnt worked well.

 

[cafe kid]

I used freeze off penetrating lube on by cb550 and it worked like a charm!

 

[manchestermichael]

ok so got one out just smacked a smaller hexhead on it but now the bleed nipple is the bitch started to drill it with a very small bit THEN SNAPED the tip of the bit IT is now in the nipple and and i cant drill it any more or get it out been trying for 3 hours but no joy i dont have any more ideas and i cant drill into the bit because it to hard and the bit just spins ??????? pic is where i am at u cant see the drill bit tip but is in there?????????????? any tips now ?