My build thread - KZ440

[ontwo]

Ok. A bit of an update. Still waiting on the oil seal. Here is why



Got the pin back in the crankshaft that seats in the backof the timing mechanism. It was sheared off. This is how it looked when I took the timing mech off



It took me the longest to drill out the old pin to make room for the new one.

I started on my seat. Not sure if I'm gonna stick with this one or start over.



Metal for the seat.





Camping foam


Here are tools I used to shape the seat


Waiting on the adhesive to set


Also worked on the cracked intake boots




More to come...as soon as the oil seal gets here.

[Gas Man]

Keep going

[ontwo]

Just realized that I have no rectifier. I'll probably get a new one from Oregon Motorcycle Parts. They come highly recommended at the Kawasaki Twin Owners Forum. I'll let you know how it goes.

[Dnyce]

id say skip the filters and go with velocity stacks, and new rubbers(theyre cheap)

each time i built my kz, ebay and bikebandit were my friends

have fun!

whats u plannin on doin to the gs?

[ontwo]

Originally Posted by Dnyce

id say skip the filters and go with velocity stacks, and new rubbers(theyre cheap)

each time i built my kz, ebay and bikebandit were my friends

have fun!

whats u plannin on doin to the gs?

Good ideas. But right now I'm going real cheap. I might add those later.

As for the GS, not sure. I may just get it running and unload it. I figure I can get rid of it easier if it is running. Also, I've got a clean title. That should help.

[ontwo]

Update.... Tonight we cooked out. After, dad and I started tinkering. We got the new oil seal in, tming mechanism on, points plate back on. Then new oil filter, filled it with oil. Reinstalled the carbs, put the tank on, hooked up the fuel line and vacuum line.

Turned on the switch, hit the button, and.....NOTHING. About that time, dad and mom had to go, my daughter wanted to play wii, so we stopped.

After some wii golf, bowling and boxing. Then some fairy tales and Spongebob book. I headed back out.

Ok, maybe we didn't line up the timing mechanism correctly? Nope, nothing. Maybe it has a clutch swich? I took the clutch cover off. Everything looked fine.

Just when I was about to go in for the night, I looked down. A lead from the starter relay was not connected. It matched the color of the wire beside it with the female connector. So WTF? it can't hurt. I plugged it in and......

SHE IS RUNNING!!!!!!!!!!!!!!!!!!!!!!!!!!!!!

So this means that the fun will now begin. Tomorrow, my wife, daughter and I leave for Gatlinburg for a few days. After that, Ms. KZ has an appointment with the sawzall.

Stay tuned........

[ontwo]

Update...

What a night. Last night I began the teardown. Getting her naked and left with a pile of parts.





Dropped her to 7" and leveled her up with some lumber



Swingarm off. Ready to SAWWWWWWWW



The aftermath



Swingarm back on



Sat the tank back on to look at something that has been bothering me....



If I use the stock tank (which I plan on), there is not going to be enough room for my seat and the battery box and electrical box at stock length.



So I've decided to stretch it some. I've got my tubing coming on Monday. I plan on making my jig to keep the alignment. (I was planning on using the swingarm). But I really think I will like it better with a stretch. It will just take a little more work. Stay tuned

[Gas Man]

You going to hard tail it?

[ontwo]

Yep. Tubing should be here Monday. Was planning on all straight tube, but now that I'm gonna add about 6", I'm thinking I will need to bend the bottom tube. Kinda dreading that, but I'll figure it out.

[Dnyce]

nothing to say, cept i like where this is going