78 kz400 cafe build

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This is my 78 kz400 6-speed cafe build. I bough this bike for $100 awhile ago but just started working on it. I am working on some rearsets and clip ons. I already drilled the rotor and started working on the seat. I just started stripping and mounting the 72' cb350f tank. I tried my hand at knee dents and it went pretty well. The tank had alot of other dents before I started. I will try to post pictures as I go.

 

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The tank will sit flat once its mounted, but right now it wont slide over the stock kawasaki mounts.

 

[treitz]

Another 400. Awesome! There a ton of KZ's poppin up on here lately.

It's a fun bike, keep us posted!

 

[MILLENNIUM FALCON]

I just finished mounting the tank. I think it will look much more vintage than the stock tank. I used a slide hammer to get out most of the old dents. I started smoothing out my knee dents with fiberglass filler.

 

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I cut out the blanks for my ankle gaurds and mounted them. I put c-clamps on them to act as pegs to figure out where I was going to mount them. I got everything mounted. Now I just need turn and knurl the pegs once I part them to length. I dont know If I want to mill slots in my ankle gaurds or come up with a pattern of holes to make it look good and loose some weight. either way I will be polishing everything once its done. So far so good.

 

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C-clamp peg (temporary) It did feel pretty good though.

 

[Epic retry]

looking good

 

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Just finished the other side. Now Im starting the controls.

 

[reelinfeele]

very nice dude. i like the speed holes. keep it up

 

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I set the engine in the frame so I can get my shift linkage figured out.

 

[MotorbikeBruno]

Very cool. I've got a stock 80' KZ440 and I may just have to start cutting it up now...dang you!

 

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it is contageous you know!

 

[valvesprung]

Very cool man. I'd be interested in a set of the rear sets without the speed holes, for my KZ400 (though a bit down the road) Sounds like a couple other guys may too if you're up for it.

Have you figured out a good brake linkage yet? Do they clear the kick start lever as they are? I have a '77 which has a much crappier lever for fitment and was told the 78-79 lever was better for this...

 

[stik70]

this is going to be a beautiful bike. Your workmanship is superb. Can't wait to see more progress!
Kev

 

[MILLENNIUM FALCON]

Yeah I will see how these turn out. As long as I have time, I would gladly make a few more. Send me a pm when you are ready.

Very cool man. I'd be interested in a set of the rear sets without the speed holes, for my KZ400 (though a bit down the road) Sounds like a couple other guys may too if you're up for it.

Have you figured out a good brake linkage yet? Do they clear the kick start lever as they are? I have a '77 which has a much crappier lever for fitment and was told the 78-79 lever was better for this...

 

[MILLENNIUM FALCON]

Thanks, I am really excited with how things are coming together.

this is going to be a beautiful bike. Your workmanship is superb. Can't wait to see more progress!
Kev

 

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All I had to do for the brake linkage was flip the lever on the drum, so it runs above the swing arm. Its not completely done yet, but It should attatch to my new brake arm with little or no bend. I will have to widen the clevis on the end because my new lever is 1/4" and the stocker was more like 12ga sheet metal. I will get you some pictures once I get it all hooked up.

Very cool man. I'd be interested in a set of the rear sets without the speed holes, for my KZ400 (though a bit down the road) Sounds like a couple other guys may too if you're up for it.

Have you figured out a good brake linkage yet? Do they clear the kick start lever as they are? I have a '77 which has a much crappier lever for fitment and was told the 78-79 lever was better for this...

 

[MILLENNIUM FALCON]

Oh yeah.....the peg clears the kicker by almost 2" on the side and about and 1" behind" As long as your not starting the bike with snow shoes on it should be fine. This was very important to me because I plan on making this bike kick only.

Very cool man. I'd be interested in a set of the rear sets without the speed holes, for my KZ400 (though a bit down the road) Sounds like a couple other guys may too if you're up for it.

Have you figured out a good brake linkage yet? Do they clear the kick start lever as they are? I have a '77 which has a much crappier lever for fitment and was told the 78-79 lever was better for this...

 

[MILLENNIUM FALCON]

Here it is. There is a split on the side but if you just need the pan i guess it doesnt matter. My internet at home is out so it might be a few days before I can check pm's, but let me know.

 

[treitz]

Thanks man. I'll get back to you after I see what exactly I want to do.

Tyler