'77 Kawasaki KZ400 Cafe Racer build project photo thread.

[jchaplin]

Since some progress has been made I thought I would start a thread here of the progress. This bike sat in a barn in WI untouched under a tarp for 5 years. It belonged to a very dear friend of mine who owned it into her 60's. She passed it on to me and now I am bringing the bike back to life. Less than 7000 original miles. Was 100% complete down to the original tool kit still being under the seat. It will be show quality when I'm done. Hope you enjoy seeing the progress. Feel free to make suggestions and share ideas.

 

[jchaplin]

More pics.

 

[jchaplin]

Fabrication begins.

 

[jchaplin]

And fiberglass work.

 

[firebane]

These bikes are VERY underestimated and go looked past so often because of the Hondas. I love my little KZ and can't wait till I can rip down the road on her.

They aren't by any means quick like other bikes but I bet with the weight reduction and such it'll bomb around in the city just fine.

Good to see your breathing new life into this bike but be warned certain parts can be difficult to find. I had to do some crazy research today to find the parts for the front wheel bearings.

 

[jchaplin]

Motor rebuild started yesterday. New piston rings, 3 angle grind, ported, new valve seals, new gaskets, new seals, Mikuni VM 30mm carbs, 1 off scrambler style SS exhaust. Rear sets, LED signals and headlight, and some other tricks I'm not going to reveal just yet.

 

[jchaplin]

These bikes are VERY underestimated and go looked past so often because of the Hondas. I love my little KZ and can't wait till I can rip down the road on her.

They aren't by any means quick like other bikes but I bet with the weight reduction and such it'll bomb around in the city just fine.

Good to see your breathing new life into this bike but be warned certain parts can be difficult to find. I had to do some crazy research today to find the parts for the front wheel bearings.

I didn't have any trouble. Ebay has worked great so far. Got all new bearings, new brake parts, front rotor getting drilled. going to 525 sprockets and chain, 2 up on the rear. Found a NOS wiring harness but not using it. Having one made because I want it smaller and hidden. Lithium battery. Going lighter every where I can. It took me awhile to find a complete bolt kit for the motor. Wanted allen heads and stainless steel, that took some searching. So much is being custom made because I was having a hard time finding stuff. New spokes on rims. Yes, I have noticed that you can't throw a stick without hitting an old honda and a semi load of parts so I thought it would be cool to do a KZ.

 

[firebane]

I didn't have any trouble. Ebay has worked great so far. Got all new bearings, new brake parts, front rotor getting drilled. going to 525 sprockets and chain, 2 up on the rear. Found a NOS wiring harness but not using it. Having one made because I want it smaller and hidden. Lithium battery. Going lighter every where I can. It took me awhile to find a complete bolt kit for the motor. Wanted allen heads and stainless steel, that took some searching. So much is being custom made because I was having a hard time finding stuff. New spokes on rims. Yes, I have noticed that you can't throw a stick without hitting an old honda and a semi load of parts so I thought it would be cool to do a KZ.

For most of the bolts you can get them through Z1 Enterprises which also has a ton of stuff for these bikes.
http://www.z1enterprises.com/Home.aspx

And you can find a lot of stuff that works on other bikes that will work on these others.

 

[jchaplin]

Cool, thanks.

 

[Powderfinger]

Looking good!

 

[El Conio]

Nice work!

 

[jchaplin]

Thanks, cylinders getting honed, new rings in route. New seals and head work done. Pics to come then motor will be reassembled and painted. Toying with some styling ideas and color combinations on the motor. I think it will match the bike well.

 

[jchaplin]

A few more details on how the seat was made. More to come on the motor.

 

[jchaplin]

Does anyone have any pics of custom exhaust work-ups or scrambler type exhaust on a cafe bike? Still waiting for new rings then motor gets put back together.

 

[jchaplin]

Breaking into the motor. Some grinding, gaskets, industrial cleaning and paint to come.

 

[jchaplin]

I like these colors. I think the more orange one is the ticket.

 

[taggat]

+10 black and orange. 8)

 

[jchaplin]

That's the one we are going for.

 

[The_Stache]

had a chance to ride a 77 kz400 today. love it. i bought it a few years ago and never did much with it and eventually sold it to my friend who just finished a scrappy tracker build with it. nice build! can't wait to see the final product.

 

[jchaplin]

Cool, I haven't ridden anything older or smaller than my old Honda cb650 I had in high school. Everything on this will either be like new or be new.