82' KZ440 Cafe' Brat Build: Carb tuning & exhaust fly by!

[M.B Co]

Been lurking here for awhile. Now that I am getting some progress done I'll throw up some specs and pictures.

Started with:

1982' KZ440 LTD, 3rd owner (free from father-in law)
15K miles, all stock

I rode it stock for awhile until I had an idea of what I wanted to do. Then winter hit and the tear down started

What I started with:

Current setup as of September 2014

IMG_20140906_112140_1 by MBCo, on Flickr

IMG_20140906_112135 by MBCo, on Flickr

IMG_20140906_112158 by MBCo, on Flickr

IMG_20140908_192322 by MBCo, on Flickr

IMG_20140908_192834 by MBCo, on Flickr



Some minor mods like signals, LED tail, bars, removal of junk, trimmed seat,

Then the tear down (no need to post every picture of me removing items)

Engine Tear down started, cleaned, re-sealed. Ready for paint. Going with Gloss Black, polished bolt heads, polished side covers

Pretty nasty

Some new parts later, cleaned up

 

[M.B Co]

Re: 82' KZ440 Build

Moved on to the frame, started some small mock ups

Dropped the forks in the tree, may switch bars or move to clip on's. Not sure yet

Uni's. Going to try the can inside. If that fails, I got some jets to throw in and start that fun process

As she sits now

De-tabbed the frame. About 1lb of useless metal. Still need to grind smooth, finish & paint

Modified my signal stalks so they attach to my headlight bucket and hold it to the ears.

Painted 1 rear shock to see how it would turn out, good imo

Painted my fork lowers. Thought they turned out pretty good. Not show quality, but should hold up to the elements well.

Random mock up, still got some work ahead of me.

shiiiiny

Needs some touch up

 

[CafeRacer650]

Re: 82' KZ440 Build

From one fellow KZ lover to another... great work! Keep it up!!

 

[M.B Co]

Re: 82' KZ440 Build

From one fellow KZ lover to another... great work! Keep it up!!

Thanks. My first motorcycle build, first Kawasaki, first KZ. Had a 04' GSXR 750 5 years ago and this little thing is a blast to ride.

 

[Shermanator86]

Re: 82' KZ440 Build

looking good man, think iv'e seen you on the twin owners forum as well

 

[M.B Co]

Re: 82' KZ440 Build

looking good man, think iv'e seen you on the twin owners forum as well

Thanks! Yeah, I go there every so often. Need to update my thread over there as well.

I get my battery tomorrow. Then I'll start the electronic pan underneath the seat, can't wait.

 

[valvesprung]

Re: 82' KZ440 Build

Diggin it! You'll definitely want different bars though. With stock foot controls super bike bars are a perfect fit on the KZ frames.

 

[M.B Co]

Re: 82' KZ440 Build

Diggin it! You'll definitely want different bars though. With stock foot controls super bike bars are a perfect fit on the KZ frames.

Thanks for the tip, I may change them out once I get it all back together.

 

[Big-D]

Re: 82' KZ440 Build

Coming along well, keep up the work

 

[M.B Co]

Re: 82' KZ440 Build

Thanks.

Going to get some work done tonight.

-Grind smooth the tabs I cut off
-Make my electrical pan
-Make the battery mount underneath the pan (battery will be mounted on it's side, terminals towards the front of the bike)

 

[M.B Co]

Re: 82' KZ440 Build

Trying to decide on tires

Should I change the rear to a 130/80-16 instead of a 90 aspect/sidewall?

 

[M.B Co]

Re: 82' KZ440 Build

Engine painted, minor things threw on to see what the look will be.

Pipes will be kept the way they are. I will just cut the very ends off and have some new tips put on, swelled at one end and I will make my own angled slash cut.

Few bolt heads will be polished also

Fins on the head and jug will be exposed alum.

 

[Big-D]

Re: 82' KZ440 Build

Looks good. This is just my 2 cents, but I would polish the fins, and the top end bolts.

 

[M.B Co]

Re: 82' KZ440 Build

Looks good. This is just my 2 cents, but I would polish the fins, and the top end bolts.

Noted that in my post. Fins will be exposed/polished, I didn't have all the bolts up top in, just had a few to hold it down. I have yet to seal it to the head. Any bolt head will be wire wheeled, cleaned, polished etc.

Thanks for the tips though. Any insight, help or opinions feel free to shoot my way.

 

[Big-D]

Re: 82' KZ440 Build

Awesome, should look good. Sorry, didnt read the last line

 

[M.B Co]

Re: 82' KZ440 Build

No,Try to find a 18" rear 440 mag,the sprocket should bolt straight on.The wheel should go straight in and give you a much more cafe look and better handling.

Understand the logic. But can I question why not? Same different if I were to get a larger wheel, being 17" or 18" with the a tire close to that size or same aspect ratio. Just the rim diameter is different.

And if I change the front to a 110/80-19, the height's will be the same.

And......I noticed the front tire on mine now is a 3.25-85-19. So going to a 80 will not be that big of a difference.

 

[M.B Co]

Re: 82' KZ440 Build

On a 16" rear wheel a /90 tire will flex more than a /80 and a /90 is probably also wider and heavier.The standard models 18"mags with standard size tires will give the most responsive handling and stability at speed.Changing MC tires is a subtle science.A 110/90 is too big.A BS spitfire 90/90 19 is a good tire and will give very direct steering.If you you want to go to fatter tires for fashion thats fine by me.If you want to go around corners I can tell you how the bike should be shod.Most small cruisers stateside had 16" rears and 18"or 19" fronts.Most the identical model type in Europe had 18"s front and rear for better handling.

Great info, thanks.

I guess in my head switching from the massive 130/90-16 to a 130/80-16 for the rear will give a better handling feel with the stock suspension. I'm not a knee dragger or a hardcore rider. Just want better than stock and I feel my tire of choice and size it should do just that.

Same thing for the front. Not looking for massive gains just a slight upgrade from stock using the stock suspension just upgrading the tires to improve the overall characteristics and feel of the motorcycle.

Style and looks does come into play.

 

[M.B Co]

Re: 82' KZ440 Build

Changed my mind I don't know how many times on tires. Finally opted for the Shinko 712's in 110/90-19 Front and 130/90-16 Rear. Good price, good reviews and I like the style of the tread.

Front Tire and other goodies will be here Friday

BikeMaster Super Bike Foam Grips (sooooo sooooooffffttttt

Random

Mock up of my battery brackets. Going to use some foam to pad it, it mounts using the cross brace holes in the rear hoop.

First round of clean up of some random parts. Wire wheel, then sand, polish, sand polish, repeat.

 

[Big-D]

Re: 82' KZ440 Build

You dropping on a new sprocket?

 

[FlyinRyan350]

Re: 82' KZ440 Build

You dropping on a new sprocket?

I'm curious too. It looks like you've got some time into cleaning the old and very worn out one.