My (winter?) project. '77 Kz400 - Page 2

CBRF2Old · 06-03-2012, 08:59 AM

Looks like you are doing a great job on this. I like the Black/Red stripe on the tank!

crash1992 · 08-13-2012, 12:10 AM

Thanks again to everyone who has complimented and helped me work on this project.
And now its.....
KZ UPDATE TIME!:
Figured it was about that time again to update y'all on what I've done since the last post.

Brakes fixed, Fork seals fixed, New tires and tubes mounted (Bridgestone BattleAxe BT45's 100/80/18, 120/80/18), Sprockets mounted.

Now, where it got interesting..... Checking out that little bit of bondo on the side cover.

Well.... It turns out it was a hole straight through the case, not fun. Good thing I bought another off ebay and put that back on instead with a new gasket.

Here's a few more pics of the damage to the old side case cover.

Pretty decent sized puncture

Nice Internal crack from where the PO dropped it and the brake lever impacted the side of the case. Not all the way through, just another good reason to change cases.

Oh hai thar! Look what I found while the cover was off, just resting in a corner. Hope it didn't bounce around in the engine too much. I didn't see any other major signs of damage while I was poking around in the engine. I'm just hoping all is well with the world and something can go RIGHT for me on this project. Haha.

Engine all back together. Also put on a Kickstarter from a '79. Folds at the bottom instead of the top. Although I had to modify the footpeg a bit for clearance, I think its worth it. It folds up flatter and fits the lines of the bike better IMO.

Frame was stripped, welded and painted(black). And now my bars don't smack my tank!

Fender Bobbed, cleaned, painted, mounted.

Battery Box made and mounted, electronics Mocked up.

TODO:
Mount/bolt down Mocked Electronics
Clean up wiring.
Install Chain.
Align and tighten rear wheel
Fab Fiberglass Seat
Paint Seat
Upholster Seat
Tune
Register/plate
RIDE!!!!!

My todo list is getting ever smaller yet!
Only a few big things to spend some money on and I'm (mostly) done!

The wiring is my major hurdle at the moment. I've got a wiring schematic, but I don't have the proper tools and don't want to "ghetto" this up even more than the PO did. Also I want to do a few small changes to the wiring. If anyone wants to see this beauty up close (but not too close, there are still flaws) I'm currently (and always) accepting helping hands from those more experienced than I.

Ming · 08-13-2012, 07:11 AM

Quote:

Originally Posted by crash1992

Very nice. I really like where this has gone.

LckyTylr · 08-15-2012, 08:50 PM

Awesome, really well done. I want a project now.

Pimpit · 08-16-2012, 04:48 AM

Looking good. I will be in town for a bit tomorrow if you still need to use my chain press. I think I might have my project bike sold, so have get back to you on when I will be over your way.

micko24 · 08-16-2012, 10:25 AM

great job man, a project indeed!

BuellCru · 08-16-2012, 11:18 AM

That picture of the metal you found in the case looks like a bullet fragment. Are you sure the hole in the side cover was not made by a gunshot? Maybe you have an old gangstas KZ.

crash1992 · 08-16-2012, 07:10 PM

Thx again guys! I'm hoping to get this all wrapped up and riding it in the next month or so.

Quote:

Originally Posted by Pimpit

Looking good. I will be in town for a bit tomorrow if you still need to use my chain press. I think I might have my project bike sold, so have get back to you on when I will be over your way.

Yea let me know man. I'm working tomorrow until 6, I txt'd you my new number.

Pimpit · 08-17-2012, 06:38 AM

Sorry, by the time I got out of the house, I was half way to nampa before I realized I left it at home

crash1992 · 12-30-2012, 12:16 PM

As always its been quite a while since I've updated this thing... So I'm just going to throw down what I've got right now. And if anyone is interested I'll post the in-between.

But I know how y'all like pictures.
In the mean time (With plenty of help from friends) I've glassed up a seat, painted, and gotten some upholstery done.

Essentially Completed!!!!!

Tail from the rear, Integrated stop/turns.

Sick upholstery done by a buddy of mine in Boise.

Whats that? You're still hear reading?
Hopefully final list before I get it bombing down the street:
Wire rear integrated light
Timing
Re-jet carbs.

e11charlie · 12-30-2012, 12:55 PM

Sweet! Can't wait to see and hearit I person.

MtnPwnd · 12-30-2012, 03:26 PM

Looks like a sick little ride. Got to love those cafe's.

crash1992 · 03-02-2013, 04:44 PM

Sooo... good news, got the tail light wired up. Bad news.... I hit a snag. While doing some of the body work and whatnot I attempted to start it at a buddy's house, we got a few nasty backfires and nothing that sounded like a motor that wanted to run. Figured it could be the cam that activates the points being 180 off, so I flipped that and its now opening at the right place/time. BUT now I'm getting no spark. Not sure if messing with the points initially before flipping the cam messed something up. Or if one of the backfires finally killed the old electronics... I'm not sure.

I am in definite need of someone who has more mechanical knowledge than I do to help me out though.
Anyone willing to lend a hand for a few hours and help me figure out why this beauty isn't firing anymore?

LckyTylr · 03-02-2013, 06:51 PM

I still can't get over how cool that thing looks.

Well done!

HaVocX · 03-03-2013, 11:25 AM

Nice work!

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06-03-2012, 08:59 AM	#41
CBRF2Old Joined: Aug 2006 From: Boise Posts: 4,890 I Ride: 83 and 84 Honda Ascot's and 91 CBR600F2	Looks like you are doing a great job on this. I like the Black/Red stripe on the tank!

08-13-2012, 12:10 AM	#42
crash1992 Wanderer Joined: Mar 2011 From: Nampa, Idaho Posts: 42 I Ride: A Cafe racer, 1977 Kawasaki KZ400s3	Thanks again to everyone who has complimented and helped me work on this project. And now its..... KZ UPDATE TIME!: Figured it was about that time again to update y'all on what I've done since the last post. Brakes fixed, Fork seals fixed, New tires and tubes mounted (Bridgestone BattleAxe BT45's 100/80/18, 120/80/18), Sprockets mounted. Now, where it got interesting..... Checking out that little bit of bondo on the side cover. Well.... It turns out it was a hole straight through the case, not fun. Good thing I bought another off ebay and put that back on instead with a new gasket. Here's a few more pics of the damage to the old side case cover. Pretty decent sized puncture Nice Internal crack from where the PO dropped it and the brake lever impacted the side of the case. Not all the way through, just another good reason to change cases. Oh hai thar! Look what I found while the cover was off, just resting in a corner. Hope it didn't bounce around in the engine too much. I didn't see any other major signs of damage while I was poking around in the engine. I'm just hoping all is well with the world and something can go RIGHT for me on this project. Haha. Engine all back together. Also put on a Kickstarter from a '79. Folds at the bottom instead of the top. Although I had to modify the footpeg a bit for clearance, I think its worth it. It folds up flatter and fits the lines of the bike better IMO. Frame was stripped, welded and painted(black). And now my bars don't smack my tank! Fender Bobbed, cleaned, painted, mounted. Battery Box made and mounted, electronics Mocked up. TODO: Mount/bolt down Mocked Electronics Clean up wiring. Install Chain. Align and tighten rear wheel Fab Fiberglass Seat Paint Seat Upholster Seat Tune Register/plate RIDE!!!!! My todo list is getting ever smaller yet! Only a few big things to spend some money on and I'm (mostly) done! The wiring is my major hurdle at the moment. I've got a wiring schematic, but I don't have the proper tools and don't want to "ghetto" this up even more than the PO did. Also I want to do a few small changes to the wiring. If anyone wants to see this beauty up close (but not too close, there are still flaws) I'm currently (and always) accepting helping hands from those more experienced than I.

08-15-2012, 08:50 PM	#44
LckyTylr Indiana Jones Joined: Jun 2007 From: Boise Posts: 1,158 I Ride: KTM's ! ! ! '07 690 SM & '13 300 XC	Awesome, really well done. I want a project now.

08-16-2012, 04:48 AM	#45
Pimpit Unicorn Joined: Jul 2008 From: Nampa, Id Posts: 4,483 I Ride: 06 GSX-R1000, 01 Yammy V-Turd 650, and 1979 Honda CM 185 Twin Star putt putt project	Looking good. I will be in town for a bit tomorrow if you still need to use my chain press. I think I might have my project bike sold, so have get back to you on when I will be over your way.

08-16-2012, 10:25 AM	#46
micko24 Big Foot Joined: Jul 2007 From: boise Posts: 1,806	great job man, a project indeed!

08-16-2012, 11:18 AM	#47
BuellCru Joined: Apr 2009 From: Boise Posts: 3,146 I Ride: Buell Firebolt XB12R	That picture of the metal you found in the case looks like a bullet fragment. Are you sure the hole in the side cover was not made by a gunshot? Maybe you have an old gangstas KZ.

08-17-2012, 06:38 AM	#49
Pimpit Unicorn Joined: Jul 2008 From: Nampa, Id Posts: 4,483 I Ride: 06 GSX-R1000, 01 Yammy V-Turd 650, and 1979 Honda CM 185 Twin Star putt putt project	Sorry, by the time I got out of the house, I was half way to nampa before I realized I left it at home

12-30-2012, 12:16 PM	#50
crash1992 Wanderer Joined: Mar 2011 From: Nampa, Idaho Posts: 42 I Ride: A Cafe racer, 1977 Kawasaki KZ400s3	As always its been quite a while since I've updated this thing... So I'm just going to throw down what I've got right now. And if anyone is interested I'll post the in-between. But I know how y'all like pictures. In the mean time (With plenty of help from friends) I've glassed up a seat, painted, and gotten some upholstery done. Essentially Completed!!!!! Tail from the rear, Integrated stop/turns. Sick upholstery done by a buddy of mine in Boise. Whats that? You're still hear reading? Hopefully final list before I get it bombing down the street: Wire rear integrated light Timing Re-jet carbs.

12-30-2012, 12:55 PM	#51
e11charlie Ghandi Joined: May 2009 From: Boise Posts: 3,674 I Ride: 2012 FZ8	Sweet! Can't wait to see and hearit I person.

12-30-2012, 03:26 PM	#52
MtnPwnd That Guy... Joined: Mar 2012 From: Mountain Home, ID Posts: 323 I Ride: 98 Honda Superhawk	Looks like a sick little ride. Got to love those cafe's.

03-03-2013, 11:25 AM	#55
HaVocX That Guy... Joined: Sep 2009 From: Boise Posts: 314 I Ride: 07 600RR Track, 71 Triumph Hardtail, 82 Honda CM400 'Street Trckr'	Nice work!

03-02-2013, 04:44 PM	#53
crash1992 Wanderer Joined: Mar 2011 From: Nampa, Idaho Posts: 42 I Ride: A Cafe racer, 1977 Kawasaki KZ400s3	Sooo... good news, got the tail light wired up. Bad news.... I hit a snag. While doing some of the body work and whatnot I attempted to start it at a buddy's house, we got a few nasty backfires and nothing that sounded like a motor that wanted to run. Figured it could be the cam that activates the points being 180 off, so I flipped that and its now opening at the right place/time. BUT now I'm getting no spark. Not sure if messing with the points initially before flipping the cam messed something up. Or if one of the backfires finally killed the old electronics... I'm not sure. I am in definite need of someone who has more mechanical knowledge than I do to help me out though. Anyone willing to lend a hand for a few hours and help me figure out why this beauty isn't firing anymore?

03-02-2013, 06:51 PM	#54
LckyTylr Indiana Jones Joined: Jun 2007 From: Boise Posts: 1,158 I Ride: KTM's ! ! ! '07 690 SM & '13 300 XC	I still can't get over how cool that thing looks. Well done!