1st build - "Dirty-Thirty" KZ440 LTD

[savheadbanger]

Damn homie, thats a lot of rust.

Nothing is actually holding the advancer mechanism on since you removed the bolt. Grab it by the shaft with some channel locks with saran wrap on the jaws or something to keep from fucking it up and give it a good wiggle while pulling straight away from the engine. Ill see if i can find my old one and snap a pic.

 

[savheadbanger]

Also soak it in pblaster or similiar.

 

[savheadbanger]

Here you go. Now you can see how its keyed on the crankshaft. Nothing holding it on except 30 years of pressure and a little rust.

 

[Doogie]

Thanks guys! That's what I thought but I didn't want to brute force it off and be wrong. I think this is the most rusty thing on the bike so far.

I'll muscle that thing off tomorrow.

 

[Doogie]

Well...update time.

I got the points off the other day and polished up the side covers. Painted and cleared the frame...sanded down the clear and waiting to add another coat or two. Prepping the wheels for paint.

Started painting the tank and of course the damn bugs come in and ruin my first two coats. I swear these gnats are the bane of my existence. Anyhow, more sanding and painting to come on that one. But I did decide on a two-tone paint that I think will be pretty badass.

Now, I'm just waiting on all my parts to arrive. And it seems like they are taking forever but I just ordered them the other day. I will be posting pics of the reassembly and most recent progress tomorrow or the next day.

Still looking for a new small, light, compact battery that won't break the bank.

 

[Doogie]

Anyone know where I can find low profile handlebar mounts???

I have been searching and I can't find any.

Thanks.

 

[Doogie]

Parts are slowly beginning to trickle in. Got tires and wheel bearings in today. Hopefully the rest will get here before Friday.

Still slowly checking things off the to-do list. Started painting the wheels today. Still fighting the shitty paint I bought for the tank. It does not like to be sanded or touched or looked at. Beyond frustrating. I'm to the point where I'm just going to get it close enough, clear it and repaint it later.

I will have a few pics this weekend when I start to put everything back together.

 

[Doogie]

Got a bunch of parts today. Man All Balls bearings are the shit!! Those things are beautiful.

Also got some nice, shiny new sprockets from Z1 Enterprises. They look great and the price was pretty damn good too.

Still waiting on a few more pieces.

Finishing the paint and clear on the wheels. Will get the tires mounted tomorrow at the shop on post - $5 a tire - then take them to the bike shop down the road to get balanced.

Should hopefully have a roller by Saturday. I won't be able to run her cause I'm waiting on some damn gaskets that won't be here til next week

 

[Doogie]

Well...opinion time.

What do you think of this...


Disregard the mess in the back. I am trying to polish the turd of a frame I have and make it unique at the same time. I have even started considering adding a damn cafe bump on the rear just to make it look a bit more smooth but I really don't want to.

Anyhow, looking into an option like this and trying to figure out how to attach it to the frame and what material to make it out of...cardboard won't hold my weight. I'm thinking thin plate steel for the sides and strips for the top then bolting a seat pan to the strips.
Welding...bolting...I just can't decide or even be creative anymore. I'm hoping some good progress this weekend will make a difference.

Tires will be mounted and balanced tomorrow. Installed new drive sprocket and cleaned and shined up rear hub and installed new rear sprocket.

Anyone know if any special tools are needed to install fork seals??

 

[savheadbanger]

All i needed to install my seals was a socket about the same size as the OD of the seals. Tapped it in with a hammer. Getting them out is another story. Have lots of small prying and grabbing tools on hand. A good set of small sidecutters would probably make short work of it though.

 

[zap2504]

I know you're on a (military) budget and you said you wanted to retain the second seat. I think your proposed design might look real "funny" given the subject bike, be fairly difficult to construct properly and not be all that comfortable.

I'd recommend using your existing seat pan and creating something like the seat from a KZ440 "G" (fairly rare in the USA; had the tank from a "B" and a cast 18 rear wheel - similar to the Z440 that was available in Europe, but without the tail). Here's a photo of one in Russia:

You will still have the stepped frame/seat (you really can't get away from it without welding) but it looks a whole lot better than the stock LTD. And much easier to construct. And if you can get a good KZ440 "B" (or '79 KZ400) tank... (BTW the OEM 2-1 exhaust from the KZ440 "B" will also fit.)

 

[Doogie]

Zap,

I am going to be meeting with my welder buddy this weekend to talk about my options and see how much work and money it will be. I am not against hacking the whole rear off to get the look I want but I will probably wait until the winter to go that route and just ride it as is for now.

I'm not too sure it will look bad or funny...I think it will be unique and different but it could look like poo. Won't know until I/we build it. I also don't think it will be any more uncomfortable than what a lot of guys are running ie. yoga mats and skateboard decks.


Pics of progress coming soon.

 

[zap2504]

OK - it's your bike. Just sayin' that working with re-bonded high-density foam and marine vinyl on the OEM pan is a lot easier and cheaper than welding (plus you still need to create a seat on top of the new tubes). And you can always go the welding route if the foam doesn't work out.

 

[Doogie]

OK - it's your bike. Just sayin' that working with re-bonded high-density foam and marine vinyl on the OEM pan is a lot easier and cheaper than welding (plus you still need to create a seat on top of the new tubes). And you can always go the welding route if the foam doesn't work out.

Correct. I know I could make something out of the stock seat pan but I think I probably won't be happy with it. We shall see what happens this weekend. I'll take a look at the seat pan and see what I can come up with.

Any links to threads or other pics of what you are talking about might spur my unmagination.

 

[zap2504]

One of the best tutorials available on re-building seats is http://www.diymotorcycleseat.com/. Lots of info/how-tos/some photos (lots of details under "Modifying Seat" tab).
Here's another photo of the Z440 (440 G in the USA). You can see that the seat base is similar to the LTD but the seat itself is taller in the front and has less of a rear step. To make one for the LTD would mean more foam for the driver's position and more up front, contoured to fit against the tank.

 

[Doogie]

Right on man... appreciate the link and info. I will definitely be looking into it this weekend. I think it will be one of those "it is what it is" things for now. I really just want to ride it for the rest of the season.

 

[Doogie]

Update time.

It's been a while...been busy with life and summer travels, etc.

So a week or so ago I got it rolling. Harley shocks are on 2nd to lowest setting. I will probably raise them up a bit for clearance. They are pretty damn stout though so they don't allow too much sag.


Then I created a seat pan and wiring/battery tray but I didn't get a pic of that...I will post it later.

Mounted a Harley headlight that my buddy gave me.



I think it looks pretty decent and it was free so I can't complain.

I changed my mind on the tank and color scheme and made it more simple for the time being. I sanded and reprepped the tank. Finalized the idea for construction of my seat but I have yet to start cause I need to borrow some tools and find the time.

Yesterday I chopped and installed my front fender. I like it for now but might chop it a bit further later. Not too sure yet.



That's about it for now.

The plan:
order clip on bars
tail light and turn signals
new master cylinder
make custom stainless brake line
mount motor and get it running
figure out wiring - clean up or rewire?

Any thoughts, comments, ideas, random words are welcome.

Thanks.

 

[Doogie]

Update:

Well finally got the motor back in and started re-hooking everything up. Ordered a bunch of parts and I am preparing for the final reassemble next weekend...damn weddings. Anyhow I have long been pondering my seat situation since I have a lovely LTD version that blessed me with a a 45 degree angle in the rear; well it's close. I finally finished up my design and started glassing. I am pretty happy with the results so far and think it will turn out well.

OK, on to the pics:
They are from my iPhone so some of them are crap. Sorry.

This first pic is my taped up, waxed up mold if you will. There is a 2X6 underneath that was originally just there for molding purposes but is now there forever because it adds a lot of strength and is completely hidden.


This is with two layers of cloth. It was my first time ever dealing with fiberglass and definitely a learning experience. I designed this to house my battery and all other electronics underneath the seat. It does so well and has plenty of space to spare. Thanks LTD frame!


Here you can see (sort of) the wooden staple strips I added near the frame hoop to aid in vinyl adhesion.

Here are a few of it trimmed up and whatnot:




I'll admit the front is very blocky and square but I'll assure you it is hidden under the tank just enough for me not to care.

I stole an old yoga mat from my sister the last time I visited her house and I slapped it on.









I love the pink.

Anyway, It needs a bit of fine tuning and some real foam on top. I will be having the wife work the leather/vinyl on her sewing machine.

Overall I am pretty dang happy with the way it turned out. You can only polish a turd so much and I damn near rubbed this thing raw.

Please comment, critique, etc.

 

[Doogie]

Update time.

Rerouted and reworked the wiring. Not at all my favorite thing in the world but it is mostly done. After much frustration and cursing I got the damn thing back together and threw a new battery in it.

After ten years of sitting around first try it started. I was amazed. It was a great moment in history. Still needs some carb tuning/jetting and I have to rewire/hook up the controls and shorten the cables but overall it is close to being done. And thanks to living on a military base I have to hook up my turn signals...along with headlight and tail light. Bah. The list keeps getting longer.

 

[DesertKZ]

Update time.

Rerouted and reworked the wiring. Not at all my favorite thing in the world but it is mostly done. After much frustration and cursing I got the damn thing back together and threw a new battery in it.

After ten years of sitting around first try it started. I was amazed. It was a great moment in history. Still needs some carb tuning/jetting and I have to rewire/hook up the controls and shorten the cables but overall it is close to being done. And thanks to living on a military base I have to hook up my turn signals...along with headlight and tail light. Bah. The list keeps getting longer.

That list never stops haha. Nice work!