KZ440 LTD

Nebr_Rex

Coast to Coast
I'm going to fix this bike up to flip. The person I got it from owes me more than what it is worth, but that's another story.
This going to be a quick turn around I hope. It will be a little different than most of the other KZ440s. The engine does have
good compression at 155/160. Here are some pics from before I picked it up.
440 1.jpg
440 2.jpg
440 3.jpg
 
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Well that brings back some memory's, was my one and only brand new bike :D
 
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Been working on a KZ650 electrical system and am about finished.
But I have cleaned up the hubs for the KZ440. Just a little hint to where I'm taking this project.


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The bike is stating to go back together after I went down to the bare frame.
Steering stem and swingarm bearing needed to be replaced. Rebuilt the wheels
with new bearings and seals. Split the cases to install a kick start and checked
the bearings. Inside the engine is really clean for the age and mileage. Main
bearings on the lower case half looked almost new, rod journals also. No. 1
rod bearing has one small groove. With Plasti Gauge the clearance showed .0015.
Cylinder bores from the bottom show no scratches but they are smooth with no
crosshatch.

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kz440 bearing 1.JPG
kz440 bearing 2.JPG
 
Been doing a little machine work for a kick start conversion using the more common KZ400 parts.
Had to narrow up the first gear cluster. Trim the dogs on the next gear over to fit in the first gear.
And machine the grooves in the KZ400 input shaft that will allow the use of the KZ440 gears.


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KZ400440 trans 4.JPG
KZ400440 trans 1.JPG
 
Transmission assembled and fitted in the upper case.
The stock 440 input shaft is on the right.
I still have to narrow the collar that is below the bottom bearing.


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KZ400440 trans 6.JPG
KZ400440 trans 7.JPG
 
what are the advantages for the 440 trans?
 
Swapping in the early KZ400 first gear cluster so I can use its more common kick start components.


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A little preview of what the finished project will look like. I have to fix the starter clutch yet.
Then I can see if the valve seals seal or not. If not I have a fresh head and new rings waiting.
The bike was stripped completely down to the bare frame and painted.
She has new bearings in the swing arm and steering stem. The wheel hubs were sanded
down to smooth out any flaws and fitted with new bearings and seals. Rims, spokes and nipples
were cleaned. Reassembly and truing of the wheels followed with new bearings and seals.
The forks have been disassembled, cleaned, sanded and then received new seals.


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KZ440c.JPG
KZ440e.JPG
 
that seat is bigger than the engine!
 
Engine had good compression but burnt oil even after it was warmed up.
Cylinders had some lite surface rust from sitting. Oil scrappers had almost no tension
and the compression rings were worn down enough to have way excessive end gap.
And while digging thru my hoard of parts I found this gasket for a late KZ400 big bore kit.


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KZ440 ring end gap.JPG
KZ440 gasket.JPG
 
Nice build you have going on. i'm currently also modifying an LTD 440 and i'm just busy refurbishing the front forks.
Already have 1 completed but i can't find the amount of air pressure for these forks, do you perhaps now how much PSI these forks require?
I couldn't find it in the manual.
 
How many KZ440 LTDs have had thier cam degreed?
Swapped the reground cam out of Dr. Jekyll.
Been an interesting couple of years, working on the bike off and on.
I'll post some pics and details within a couple of days.


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Looking nice and clean man! Did you recover that seat yourself?- it looks really well done
 
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