'80 KZ750 Twin - Project:WARHORSE

dp9

Member
Re: '80 KZ750 Twin - Project:WARHORSE - RUNNING VID!

SHE'S ALIVE!!!




I know, I know, cell phone vid sounds is terrible. I'll get a better one up as soon as I get it to the riding stage. Sounds raspy and pissed off when you crack it (I'm in love), but almost smooth when at a constant rpm. The factory H-pipe probably helps that.


Thats my friend Rick on the bike. He's the same guy who wired up my 360. Speaking of Rick, remember the other bike I mentioned in the beginning of this thread, the one that is in the back of the civic? I gave that to him for helping me with the wiring on my 360. The motor was seized and it had a small animal nest INSIDE THE CARBS! He got it running the other day. yeah, I'm impressed too.



after a full night of fucking with the timing and carbs, she runs and even fucking idles! not perfect by any means, but at least its a place to start tuning from. I'll get to that as soon as the swelling in my foot goes down from kicking this thing over so many times tonight.


I'm pretty relieved that it runs considering the shape it was in when it entered my garage 6 months ago.


the head and tail/brake lights dont work. blinkers are good, though. As soon as I get those sorted out I can start to ride then really dial it in.
 

dp9

Member
Re: '80 KZ750 Twin - Project:WARHORSE - RIDING VID!!

one of my buddies taking her out on an inaugural ride:




he said its really dead on the low end actually dies when slowing down if you dont keep the revs up enough, as you can see in the second vid. but its like flipping a switch once the rpms get up a little bit. so much so that he pulled the front tire up @ 46 seconds in the first vid (difficult to see, I'm taking his word for it).

I'm thinking the timing might be off slightly, plus the advancer needs new springs. Otherwise, I'll up the pilot jet. I have BS38 carbs and the pilot jets are 45's right now (stock is 40). I picked up 47.5's and 50's at the same time, so we'll see how it goes. still gatta do some plug chops, but it revs like the needle position and main jet are ok. Main jets are currently 132.5, stock is 125. havent touched the needles.
 

JRK5892

New Member
Re: '80 KZ750 Twin - Project:WARHORSE - VIDS!!

she sounds great! glad she is up and running now just dial her in
 

dp9

Member
Re: '80 KZ750 Twin - Project:WARHORSE - vids and she's done.


Thanks jrk. I'm pleasantly surprised by the exhaust note. my friend in the riding vid has a kz440 with a reground cam and 13.5:1 static compression (DCR is less due to longer duration intake lobes) and I'm amazed at how similar the two bikes sound. His is slightly raspier with slightly less base in the note, but otherwise they are very similar.

So it turns out popular opinion says this bike is pretty damn cafe, and about 0% bobber. I just set out to build something that looked aggressive and cool and thats what it turned into. guess the thread is in the wrong place. oh well, the build is pretty much over. after I get the head and tail lights working I'll register it, ride it and thats that.


If I end up doing anything else major to it I'll start posting here again. thinking about a bratt style seat over the winter.


I'll update here and there on tuning if anyone expresses any interest, but otherwise theres not much else to tell.




Thanks for following along guys!


-DP9
 

Griff5268

New Member
Re: '80 KZ750 Twin - Project:WARHORSE - VIDS!!

YES! Change the seat and sell me that one!...lol.. Already messaged you. Great builds man.
 

dp9

Member
Re: '80 KZ750 Twin - Project:WARHORSE - VIDS!!

laugh. tell ya what, you find me a nice thinly padded bratt style seat and I'll trade you.
 

dp9

Member
Re: '80 KZ750 Twin - Project:WARHORSE - VIDS!!

since I'm on here I might as well say something about the tuning progress I made today. got some clear plastic tubing and used it as a sight glass to check the fuel lever. set the floats to the low side of the stock range. put in bigger pilot jets. 40's were stock, I had 45's in, today I put in a set of 50's. Adjusted the idle screws to the recommended (by someone on the interwebs) 1.5 turns out from lightly seated. Oh, and I changed the oil because it looked like this:

good amount of smoke started coming out of the breather so I shut her down and did an oil change. probably had a bunch of fuel in it from (unsuccessfully) trying to kick it over so many times in the the past 2 weeks. now she is easier to kick over, starts after 2 or 3 tries and runs muuuuuch cooler. I put in a bigger capacitor as well, which is why it takes a couple kicks to start.

Now I just have to figure out why the head/tail/stop lights dont work and I'll be riding it everywhere.


Oh yeah, and I decided to wrap the pars in hockey tape, and then sprayed them with rubberized undercoating to keep it from getting sticky. didnt really work too well, there is still a bit of tack to them. next I'm going to spray them down with a can of truck bed liner I have laying around and see how that works. I'll post some pics of that soon. the bars look small as hell (diameter wise).
 

dp9

Member
laugh, thanks man.


lil update:


i tried to figure out the wiring problem and ended up taking the whole harness out and redoing it completely. made a new electronics mounting plate under the seat which the cap, regulator, fuse box and flasher bolt to. looks pretty clean if i do say so myself :D . I'm adding a switch for all the lights in the system so they arent draining charge from the cap when I'm trying to kick it over. If it wont do all the lights it will do the head and tails.


I changed the front end too. removed the gauges and idiot lights, none of which worked, raised the headlight up a bit to fill the some of the void left by the gauges, moved the bars on top of the top triple. Put the front blinkers in the factory location because the bars are out of the way now.


I took the cam cover off because it was pissing oil due to a snapped bolt. in the process of removing it I snapped another one. waiting on a friend who welds to come over and put a little handle on them so i can vise-grip them free. while the cover was off I painted it wrinkle black with truck bed liner. looks bad ass. shouldve used more of that stuff.


I should have the bike back together by tomorrow. I'll take some pics of the new stuff.
 

dp9

Member
finished soldering up the wiring. as soon as my friend welds a handle on the bolts i need to vicegrip out I can start the thing and see if it all works. threw the front end together for a crappy camera phone photo shoot. looks less cluttered and a little more upright and pedestrian. still good though. check the pics.







pic of the bars in the hockey tape wrap.





I had these holes in the sides of the tail section from some blinkers i used. I need a kill switch for all the lights when im kicking the bike over. I mounted it here. why not.
 

dp9

Member
yup. working on tuning it. ive got a hard starting problem. well, i had a hard starting problem before, then i upped the jets and now its worse. not sure if its a carb or ignition problem. I think that im not getting enough spark due to the capacitor and the fact that its kick only. so this weekend im testing the coil, i ordered new points and im going to pick up a new condenser too. if the coil is good, and the new points and condenser dont do anything, I'll probably grab a relay from the local autoparts store and do the coil mod which essentially wires your coil straight to the battery (or in this case the capacitor) instead of running the power all the way through the harness and to the controls, etc. I'm really hoping the coil is bad, because otherwise im not really sure whats wrong and ill just be replacing everything until it works. ive been testing the bike with a set of wires hooking the cap up to a good, charged car battery, so ive def got the volts and amps to run the thing, but she just wont cooperate at the moment.

I did have to cannibalize the rear shocks for my cb360, so the shocks that were on the 360 are now on this bike (black with piggy backs orig from a vf750). theyre a little shorter, but i think that will actually aid in traction when goosing it out of corners (it used to unintentionally "drift" a little bit).
 

Vix

New Member
Just picked up my own '80 KZ750G Twin that my boyfriend will modify. Read this thread start to finish, just amazing work here on the Warhorse!! The first page or two I just couldn't believe how much work you had in store but you really made it happen. Awesome!! :)

Wish I could hear it run (might give me an idea what mine will sound like although I ordered a 2-1 exhaust) but for some reason the video link isn't working for me, maybe it's my browser though. I'll try again another time. :)
 

dp9

Member
Thanks! I actually enjoyed that build. it went relatively smoothly and didnt take as long as i thought it would. a few people have said similar things about the disparity btwn the begining and end of the project, so i actually went back and re-read the first couple pages just now. i forgot how bad it looked, laugh. phosphoric acid did most of the work for me, its fantastic at removing rust. just take a rusty part off, drop it in the vat of acid, and the next day its rust free and ready for paint.
 

dp9

Member
finally got around to tuning this thing again. had a terrible starting/running problem. new set of points and a condensor and she starts on the third kick, but only on one cylinder. took the carbs off and cleaned them (for the third time), bench synced them, installed some inline stone filters and BAM! she runs better than ever! doesnt want to keep the front tire on the ground, and the back tire walks a little if you throttle it out of a turn :D might need some new rubber, too.

still have a little idle problem on one side, i think i might have to install a bigger pilot jet on that side. that doesnt sound right to me, but im adjusted all the way and its still a little lean on the right cylinder. not bad though.
 

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