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fredd7924
01-09-2011, 6:22 PM
I have a 76' kz400 that I've been working on for the past few months, and I have a few questions, so I figured I would start a thread to get everyone's inputs since I saw a few other members here have kz.

So it started out with a good deal found on craigslist for $250 with a title. I wasnt really sure what I was gonna do with it when I bought it, but I quickly realized that I wanted to do a old school bobber style but on a cheap budget. This is the ugly thing that I started with.
http://i1099.photobucket.com/albums/g390/fredd7924/DSC00274.jpg
started to strip it the first day that I got it.
http://i1099.photobucket.com/albums/g390/fredd7924/DSC00315.jpg
got it down to just the essentials
http://i1099.photobucket.com/albums/g390/fredd7924/IMG_3472.jpg
at that point I was debating on what to do next. I considered just cutting the top tubs off and welding straight bars down to the sway bar to make a quick hardtail. So i decided to actually cut it up and make a real hardtail. Since I don't have access to a tubing bender or a mill to make the axle plates, I decided to spend the couple extra dollars and get the TC Bros hardtail kit.
The kit saved me a bunch of time as a first time builder as it took a couple variables out of my problem. I cleaned all the old tabs and bars off the main frame section
http://i1099.photobucket.com/albums/g390/fredd7924/IMG_3625.jpg
I don't have a jig, so I used the stock swing arm to keep everything square, I tack welded a piece of flat stock to the back of the original axle plates and c-clamped the new ones behind it.
http://i1099.photobucket.com/albums/g390/fredd7924/IMG_3650.jpg
http://i1099.photobucket.com/albums/g390/fredd7924/IMG_3651.jpg
http://i1099.photobucket.com/albums/g390/fredd7924/IMG_3652-1.jpg
http://i1099.photobucket.com/albums/g390/fredd7924/IMG_3653.jpg
After I got the lower bars welded on, I took out the swing arm as it was sturdy enough to keep everything aligned. I got a sportster tank mounted so I knew where about I wanted the seat. I wanted the seat as low as possible, so I kinda guesstimated where I wanted the top tubes to be.
http://i1099.photobucket.com/albums/g390/fredd7924/IMG_3656.jpg
here you can see how I cut the end of the tubes to be notched out for the axle plates, I'm not sure if this is the proper way to do it, but it seemed like the best way. I used a bandsaw to cut these out.
http://i1099.photobucket.com/albums/g390/fredd7924/IMG_3657.jpg
http://i1099.photobucket.com/albums/g390/fredd7924/IMG_3660.jpg

cboone1010
01-09-2011, 6:37 PM
thats a hell of a good start. looks like its going to be an awsome sled.

fredd7924
01-09-2011, 6:38 PM
I used a 110v welder, which is a little underpowered for this application, and I'm not the worlds greatest welder, but I think that I shouldn't have any problems with these welds.
http://i1099.photobucket.com/albums/g390/fredd7924/IMG_3661.jpg
I made a seat pan also. I just roughly sketched it out on a piece of thick paper then transferred it over to the steel. I put a little bend on it and used sbc valve springs and retainers for the springs. I used a heavy duty door hinge for the front hinge. Once i had an idea of what the seat was gonna look like, I was able to weld the top cross bar in.
http://i1099.photobucket.com/albums/g390/fredd7924/IMG_3668.jpg
I put the engine back in to mock the rest of the things up.
http://i1099.photobucket.com/albums/g390/fredd7924/IMG_3672.jpg
I covered the seat, although it isent fully finished. I used carpet foam stacked ontop of each other using spray glue in between. Than I used a belt sander to shape it the way i wanted it. I still need to put a cover on.
http://i1099.photobucket.com/albums/g390/fredd7924/IMG_3818.jpg
I am using an old ammunition box for the battery box, Its gonna be a little difficult to stuff everything in there, but I think I can get it to work. The rectifier will be bolted underneath the battery box so it won't overheat. I got a gold chain, cause I thought it looked neat. It's hard to see but I also made a license plate bracket with a small light above it. I got a older Harley headlight for the front too.
http://i1099.photobucket.com/albums/g390/fredd7924/IMAG0099.jpg
Here is how it sits now, I got a set of bars, but I'm not sure that these ones are low enough, but they will do for now. I ran it, but I really need to figure out some type of muffler set up because I don't think my neighbors like listening to it. I also need to finish wiring it up, get some type of air filter, a mini speedo.
http://i1099.photobucket.com/albums/g390/fredd7924/IMAG0103.jpg

Vinny
01-09-2011, 7:18 PM
That looks good. Seat is super low. How much did you stretch the rear end. I like the exhaust. Not a fan of the tank but thats just personal style.

You using the stock front fender for the rear fender? Its a good start. keep working and keep us posted.

SilverBurr
01-09-2011, 8:28 PM
I used a 110v welder, which is a little underpowered for this application, and I'm not the worlds greatest welder, but I think that I shouldn't have any problems with these welds.

Those welds are good. :cheersmate:

fredd7924
01-09-2011, 8:55 PM
Its stretched about 4", mainly because thats where the new axle plates butted with the old ones and it seemed like a good length.

I did flip the front fender around to the back, Its mounted at the cross bar under the seat and the lower cross bar. Its pretty sturdy and I don't think I will have any problems, I still need to cut off the old little taps which are at the top, but I was unsure how stable it was going to be so I temporary left them on just incase. I'll get a closer picture of my mounting later on.

I am really stuck on what I want to do with the exhaust. right now i just have the stock tubes coming down, but its way to loud and I need some type of muffler, and unsure if i want to do a 2 to 1, run them both ontop each other on one side, or one on each side.

sackman
01-10-2011, 3:07 PM
I like it. Simple clean and low!

Salty
01-10-2011, 3:27 PM
really like the strance of this kawi... damn i need a good paying salary so i can stock my fleet.

melville
01-12-2011, 4:52 PM
looks good. I'm building my CM400 bobber right beside a 55 as well.

NHMike
01-12-2011, 5:15 PM
Looks killer!! Hopefully the IH won't shit itself this year and I can get started on my 400.

Vinny
01-12-2011, 6:50 PM
You gotta run some kind of exhaust. The pipes with no silencer will make it really hard to tune. I found that without a 2-1 and a silencer my bike had less power and bad compression. (I am not 100% on that because the headgasket was shot too but the exhaust work really helped it. ) Keep going. Great work so far. (I love these bikes)

fredd7924
02-12-2011, 7:01 PM
I worked on it a little bit more today, I ordered a set of these muffler inserts to help keep it a little quiet. they are pretty cheap and should just slide into my header tubes.
http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&item=270703120889
Here is a picture of my license plate mount/taillight. you can also see how the rear fender is mounted. I will cut off those little tabs at the top later on.
http://i1099.photobucket.com/albums/g390/fredd7924/IMAG0018.jpg

I also played with my battery box a little bit, I might have better pictures tomorrow.
http://i1099.photobucket.com/albums/g390/fredd7924/IMAG0019.jpg

CriminalKZ
02-12-2011, 11:03 PM
Looking good dude, I'm doin a 440ltd right now so this is good to see

Ember
02-13-2011, 2:00 AM
Is this your first build? You're doing a hell of a job. I like how you mocked up and built your frame. Good idea on making sure to add the gussets where your tail section was welded to the cradle. At some point, if you can get that tank to sit lower, I think it would really flow well with your bike.

fredd7924
02-13-2011, 4:09 PM
I worked on it a little bit more today and was able to ride it up and down the street for the first time. I was surprised how well it ran. I still need to finish wiring the lights, but I got the box in with the battery and the ignition switch. Here is a picture from the end of the day
<a href="http://s1099.photobucket.com/albums/g390/fredd7924/?action=view&amp;current=IMG_0941.jpg" target="_blank"><img src="http://i1099.photobucket.com/albums/g390/fredd7924/IMG_0941.jpg" border="0" alt="Photobucket"></a>

Ember- this is my first motorcycle build, but I also have a 69 Camaro that I resto-moded over the past couple years, so a motorcycle build is an easy transition.

gs650
02-13-2011, 4:43 PM
Your bike looks awesome. Where in Pa are you? Also got any pics of your camaro? I have a 67 I've been building.

Ember
02-13-2011, 6:29 PM
Looks great! Just a suggestion- I would cap the tubes on your tail section so water doesn't collect in there.
So, how'd you like the ride? :)

CriminalKZ
02-13-2011, 6:52 PM
Did u have to rejet the carbs with the pod filters?

ninjaracerchick
02-14-2011, 8:52 AM
Found a great jet kit on eBay. The company completely customized my kit to fit what I'm doin to the bike, including alt

fredd7924
02-14-2011, 6:36 PM
My ride up and down the street was pretty short as I still do not have my baffles set up yet and did not want to upset the neighbors too much. It felt pretty good for how short it was and didn't bog out or anything, but I'll look into seeing if I need to change the jets after I get the exhaust on and start riding it around.

Any good tips on how to cap off the ends of the tubes as mentioned? or should I just cut out some thick sheet metal circles and weld them on and grind?

Does anyone have a suggestion on what to use for a speedo? I want a mini pod speedo I suppose, but unsure on the ratio or where to get one.

I'll get more pictures and updates later, as I usually only get a chance to work on it every weekend or two. but here are a couple pictures of my Camaro, which is still kinda a work in progress.
Before
<a href="http://s1099.photobucket.com/albums/g390/fredd7924/?action=view&amp;current=IMG_1248.jpg" target="_blank"><img src="http://i1099.photobucket.com/albums/g390/fredd7924/IMG_1248.jpg" border="0" alt="Photobucket"></a>
Subframe off
<a href="http://s1099.photobucket.com/albums/g390/fredd7924/?action=view&amp;current=IMG_1858.jpg" target="_blank"><img src="http://i1099.photobucket.com/albums/g390/fredd7924/IMG_1858.jpg" border="0" alt="Photobucket"></a>
A few steps later....
<a href="http://s1099.photobucket.com/albums/g390/fredd7924/?action=view&amp;current=EngineCutaway.jpg" target="_blank"><img src="http://i1099.photobucket.com/albums/g390/fredd7924/EngineCutaway.jpg" border="0" alt="Photobucket"></a>
Current
<a href="http://s1099.photobucket.com/albums/g390/fredd7924/?action=view&amp;current=IMG_0961.jpg" target="_blank"><img src="http://i1099.photobucket.com/albums/g390/fredd7924/IMG_0961.jpg" border="0" alt="Photobucket"></a>

lobstermobster
02-14-2011, 6:51 PM
i have a kz650 and the only info i could find on the speedo ratio is that the usual standard for most jap bikes used 2240:60 for the mechanical speedo ratio.

And i have been looking around for one and the only mini mechanical speedo i could find was 60 bucks and had 4 led indicators. I dont know how much you are looking to spend, or what you are looking for in a speedo, but i would rather pay less than half that and they can keep their indicators and any other doodads.

gs650
02-14-2011, 8:53 PM
your camaro looks good. I was thinkin of painting mine flat black awhile ago. Mike's xs has a couple different speedos to pick from. I don't know what ratio you need though.

Ember
02-14-2011, 10:50 PM
For the end caps, you can cut them out with a small hole saw, or if you have one, a chassis punch. Just cut them in half, weld, and grind flush if needed.

keesdapp
02-14-2011, 11:42 PM
Great car
We dont see them much overhere

Ghosttown
02-15-2011, 10:25 AM
You have some great builds man! Love that Camaro, wicked stance.

dckareem
02-15-2011, 3:14 PM
good shit. Making my 440 rigid instead of brat style next week.

turtlem1969
02-15-2011, 6:41 PM
dont know which one looks better, the bike or the car. outstanding job on both.

radon220
02-18-2011, 2:57 PM
Looks great! How's the position of the foot rests, shifters, and brakes with your lower @ss position? Seems like you'd be cramped up, but maybe I'm wrong.

I've got a stock KZ440... I'm takin' notes!

kustomville
02-18-2011, 5:06 PM
just bought myself a nice old KZ 400, from 1979....

gotta check some ideas froms ya....

the wiring is it simplified..??
got any wiring photo around.....:clap for you:

fredd7924
02-19-2011, 5:53 PM
Thanks guys. The riding position is a little bit cramp as I am using the stock peg locations for now, I might lower them later on, but just to get it going they will be in the stock spot to keep it simple. I think is kind of a confortable position, but I'll see how it works out on longer rides.

As far as wiring.....I started with the original harness and started cutting wires off and cutting wires off untill I was at the point where I had nothing but the original ground and power wires....so essentailly I don't have a harness, once I get my wiring complete I can throw together a quick Paint picture of the diagram

I don't think I'll have time to work on it this weekend, but am hoping to get it registered and taged within the coming weeks. The only problem is I want antique tags for it as I do not need to get yearly inspections and there is no yearly registration fee. But to apply for the antique tags, I need 4 clean photos of a stock kz400, front, back, side, side (no angles). Does anyone have pictures of their stock kz400 that I could use?

rigatoni
02-21-2011, 10:28 AM
I worked on it a little bit more today, I ordered a set of these muffler inserts to help keep it a little quiet. they are pretty cheap and should just slide into my header tubes.
http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&item=270703120889
Here is a picture of my license plate mount/taillight. you can also see how the rear fender is mounted. I will cut off those little tabs at the top later on.
http://i1099.photobucket.com/albums/g390/fredd7924/IMAG0018.jpg

I also played with my battery box a little bit, I might have better pictures tomorrow.
http://i1099.photobucket.com/albums/g390/fredd7924/IMAG0019.jpg
Where did you put all your other electrical? in the top of that ammo box? looks like from the picture you have to take everything out to get the battery out?

fredd7924
02-21-2011, 8:39 PM
Pretty much the only pieces of the electric system that I have to worry about are the Battery, Ignition switch, rectifier, and voltage regulator. The voltage regulator is at the bottom of the box with the battery sitting on top and the ignition switch ontop to pin it all down. The rectifier i was worried it might be a bit heat sensitive, so I bolted it underneath the battery pan and cannot be seen.

To remove the battery i have to remove the switch, which is a bit of a pain, but I figured I will almost never need to remove it as I can charge it where it sits. I can try to get a picture of the placement of the pieces this weekend.

rigatoni
02-22-2011, 1:13 AM
cool looking good!

fredd7924
05-15-2011, 7:18 AM
Well I did'nt have much time to work on it between other projects and school, but I got it all finished up a couple days ago. Here are a couple pictures
I got it back down to the frame to paint it. I just used satin black rustolum in the cans from lowes and put it in my HF spray gun. The paint came out decent, better than spray bomb.
http://i1099.photobucket.com/albums/g390/fredd7924/kz400/IMAG0099-1.jpg

I put it up on my little cart for final assembly, It made things easier
http://i1099.photobucket.com/albums/g390/fredd7924/kz400/IMG_1206.jpg

Putting some more junk back on the bike
http://i1099.photobucket.com/albums/g390/fredd7924/kz400/IMG_1212.jpg

The bike mostly finished, poor lighting
http://i1099.photobucket.com/albums/g390/fredd7924/kz400/IMG_1214.jpg

I had to modify my pod filters, as they were hitting the frame rails, So I took the caps off, cut a section out, welded a new lip in, then siliconed it back together
http://i1099.photobucket.com/albums/g390/fredd7924/kz400/IMAG0091.jpg

I found this wiring diagram somewhere on this forum, and it was very helpful, thank you to whoever made this.
http://i1099.photobucket.com/albums/g390/fredd7924/kz400/kz400-wiring-kickonlycopy.jpg

I'll get some more pictures of the little details when its nicer out, it's all wet outside right now.

fredd7924
05-15-2011, 8:16 AM
I had a few minutes to waste this morning while waiting for the roads to dry, so I snapped a few new pictures.

Here you can see my rectifier is bolted under the battery box, and usually pretty hidden, it also gets alot of cooling here. you can see how my exhaust exits and why I needed to modify the pod filters.
http://i1099.photobucket.com/albums/g390/fredd7924/kz400/IMG_1304.jpg

Here you can see my rear brake setup, nothing too fancy
http://i1099.photobucket.com/albums/g390/fredd7924/kz400/IMG_1302.jpg

Here is whats hiding in my battery box. the voltage regulator sits on the very bottom, battery sits ontop of that, then the ignition switch slides in over the battery, acting as a holding device. If I need to charge the battery, I will just do it while it's in the case.
http://i1099.photobucket.com/albums/g390/fredd7924/kz400/IMG_1315.jpg

I crossed the right exhaust over to the left, I think i like it better this way, but unsure. I might also wrap the exhaust with tan wrap, but unsure about that.
http://i1099.photobucket.com/albums/g390/fredd7924/kz400/IMG_1306.jpg
http://i1099.photobucket.com/albums/g390/fredd7924/kz400/IMG_1312.jpg

Things I have left to do are cover the seat, clean up some of the wires going to the battery box, re-jet the carb, maybe change the bars to something slightly lower? maybe change the front brakes to something less gaudy.

BingTheBarber
05-15-2011, 7:51 PM
just read the whole build so far... and man its realllllyyyy making me want to do one of these... looks like these things can be had for pretty cheap!!

how much do u have into it so far?

fredd7924
05-15-2011, 8:23 PM
I added it up yesterday and I only have about $550 into it. Here is a quick break down

Initial Bike 250
Hardtail Kit 150
Taillight 30
Handlebars 25
Used Tank 30
pod filters 20
exhaust baffles 20
seat 5
Battery 23
battery box 7
ignition switch 10
mirrors 12
Chain 30
headlight 20

old fairings -100
old starter -30
old plastics -30
old misc -50

Tags/registration/title 105

Total to get on road $527

BingTheBarber
05-15-2011, 8:36 PM
I added it up yesterday and I only have about $550 into it. Here is a quick break down

Initial Bike 250
Hardtail Kit 150
Taillight 30
Handlebars 25
Used Tank 30
pod filters 20
exhaust baffles 20
seat 5
Battery 23
battery box 7
ignition switch 10
mirrors 12
Chain 30
headlight 20

old fairings -100
old starter -30
old plastics -30
old misc -50

Tags/registration/title 105

Total to get on road $527

w0w man!!!!! not to shabby!!!!! i wish i could find one that cheap!!!! hell im looking for any bike for under 1000 right now lol!!!! i was looking for an xs650... but this build is making me change my mind! loving the way its coming out... and how cheap your doing it!

poonslammer
05-15-2011, 9:07 PM
nice bike man. i would have liked to see how you got it off of that cart though :rolleyes:

CanineMerc
05-15-2011, 9:44 PM
Nice build man!

fredd7924
05-16-2011, 7:52 AM
Does anyone have any good information about jetting it or where to buy a jet kit?

I found this one on ebay, for about $59 shipped, maybe I am just being cheap, but I was expecting to spend about half that? any cheaper alternatives or sources to do this before I order this one?

http://cgi.ebay.com/ebaymotors/Kawasaki-KZ400-KZ-400-Z400-Twin-Carburetor-Carb-Jet-Kit-_W0QQcmdZViewItemQQhashZitem4cf6c312e6QQitemZ33055 7493990QQptZMotorcyclesQ5fPartsQ5fAccessories

Thanks

Sighless
05-16-2011, 9:54 AM
If you are going to try and tune it for maximum performance than that's sounds about fair. When you buy jets it's like 5.99 for pilot jets each or 12.99 for 4 (plus shipping) main jets are about the same. So if you guess and get close and it runs alright you're still looking at around $30 IF you get it right on the first guess. If you get the kit then you can dial it in how you want it and have the parts if you need them or to make adjustments if you decide to take your bike into the mountains or below see level etc... or just sell the rest in the classifieds. IMHO anyway.

KKAPP
05-19-2011, 9:48 AM
I've always kinda liked KZs, but now I definitely want to snatch one up if I can get it to look that good for just over $500. Good work, dude.

fredd7924
05-25-2011, 7:26 PM
So I got pulled over today while putting around a neighborhood slowly. The cop stops me and says I pulled you over for your license plate not being mounted properly (vertical). Then after he gets out his rule book gets to looking at it and says you also do not have turn signals....front fender.....chain guard.....horn.....white tag illumination. Somehow he missed that I have no speedometer or gauges?

Then he asked if it was like this when I got it inspected last month, he said no (as not to get the inspector in trouble), I took off the parts afterwards. So he said I have 10 days to put them back on and bring it back to the station or receive a fine of over $100 for each violation.

It's a good thing I sold all the old parts I didn't use, the bike is freshly painted, and all wired nicely :banghead:

dok7997
05-25-2011, 8:16 PM
Thats what getting picked on in school will do for ya. That ass hole. ACAB!!!!!

DarkEgo06
05-25-2011, 9:17 PM
This is an AWESOME build! I have been looking at buying a bike to turn into a bobber and i LOVE this frame for turning it into a hardtail the way you did. (saves alot of measuring and blocking). Does anyone know if the 650 frame is similar? or know of a bigger bike that have a frame that i could do the same thing to?

Great thread, thanks for all the time you put into it!

fredd7924
05-25-2011, 9:55 PM
last week I decided to buy the jet kit from Sigma Racing on Ebay for about $50. This was a little bit more than I wanted to pay, but I got lazy on doing my research as I am not very familiar with jetting and just wanted the bike to run better so I could ride it. So it gets here and I was a bit disappointment in what the kit contained....3 drill bits, a few washers, 2 45 jets, and a thick book.
http://i1099.photobucket.com/albums/g390/fredd7924/kz400/IMAG0132.jpg

After reading into the book, all that was necessary to correct the 1/4-3/4 throttle stumble was...replace the stock 35 jets with supplied 45 jets, turn the mixture adjustment screw on the side of the carbs out 2 full turns from being seated (mine was about 1.5 turns when I started), and place .050" worth of washers under the main jet needle. It says if its still running lean to drill the jet out to 55, then again if still not satisfied. It also came with a couple other little tips, diagrams, procedures, yadayadayada, but that is the basic information. I do have to say that it does run great now, HUGE difference, but this kit mainly paying for that book, not the materials.

If I had to do it it over again or what I would suggest to others is....
1. purchase 45 main jets or (i think this is the same to drilling out to about .045")
2. put .040-.050" worth of shims/washers under main needle to effectively raise it.
3. find the mixture screw on the side of each carb, turn it in until seated, then back out 2 full turns

volcomskater77
05-25-2011, 10:07 PM
i love this build man. im in my xs400 for a little over 5 right now. where did you got that batter? and what kind is it?

BingTheBarber
05-27-2011, 10:19 PM
dude that really sucks about that asshole cop!!!!!!!!!!!!

coma13
05-28-2011, 10:26 AM
I've never been clear, but is there any specific word of law that says that your turn signals have to be wired through the main electrical system of your bike? Or that they have to both be activated from one location?

If not, strap a couple of flashing bicycle taillights on either side of your bike and just push the button on each one to turn it on and off.

ninjaracerchick
05-28-2011, 9:15 PM
i bought mine from the same people. great info, good price... especially if your like me and had no idea what your doing ;)

zero
05-29-2011, 9:41 AM
I have seen people make a secondary harness with turns, tag illumination, horn, etc and if/when ticketed, just piggyback into your system and ziptie it to the bike just for inspection. I have even seen guys strap an extra small battery to their bike just to power the piggyback harness....

When I brought my 77 shovel head through inspection for the first time, the inspector said 'right turn signal' and I used the hand signal. Did the same thing with the left and he passed me (even though the bike came from the factory with turns).

yfzmotox21
05-30-2011, 11:40 AM
its that the universal hard tail kit from tc bros?

fredd7924
05-30-2011, 4:19 PM
i love this build man. im in my xs400 for a little over 5 right now. where did you got that batter? and what kind is it?

I bought the YTX4L-BS battery for $23 shipped off of ebay. I wasn't sure that it was going to work at first, as it is only a 3AH and extremely small, but it seems to be working fine now. When I first got it I underestimated how small it really was and the battery will die after a couple minutes if you leave the ignition on as the coil and rectifier pull a few amps. I just start it right after I turn the key on now.



yfzmotox21- yes I used the TC bros hardtail kit. I believe it was about $150. If I had a tubing bender I would have tried to make my own, but this kit was easy at the time.

fredd7924
06-07-2011, 4:01 PM
To comply with the local police, I added turn signals, chain guard, front fender, and horizontal plate. I'm sure this is not what they were thinking when they said I needed a chain guard, but it only took me 5 minutes to rig up and it kinda fits the theme. I'll prolly try to find a plate which says antique or something on it instead of truck.
http://i1099.photobucket.com/albums/g390/fredd7924/kz400/IMG_1372.jpg
The turn signals are almost invisible unless you are looking for them or they are lite. They are mounted under the seat and light up amber only when lite.
http://i1099.photobucket.com/albums/g390/fredd7924/kz400/IMG_1373.jpg
http://i1099.photobucket.com/albums/g390/fredd7924/kz400/IMG_1419.jpg
Here is the underside of my seat with the new lights mounted. You can also see how I pulled the leather around and just used self tapping screws to hold it in. You will also see the right valve spring is broken. I hit a bump on my last ride and my seat fell side ways scaring the shit out of me, but no big deal as I have a box of old valve springs.
http://i1099.photobucket.com/albums/g390/fredd7924/kz400/IMAG0139.jpg


I really do not like all the extra "junk" on the bike, but I also do not like fines, so this is a moderate compromise. I also have a bicycle speedometer mounted on the handlebars, and a horn on the bottom of the bike, maybe some better pictures later

fredd7924
12-01-2011, 11:13 AM
It's been awhile, but I did a couple little things to it. I took off the ugly chain guard and front fender. I also put a straight tread tire on the front. I also got around to sealing the leaky gas tank and replacing the fork seals. Here is a couple updated pictures.
http://i1099.photobucket.com/albums/g390/fredd7924/kz400/IMG_3083.jpg
http://i1099.photobucket.com/albums/g390/fredd7924/kz400/IMG_3079.jpg

kawijake
12-01-2011, 1:07 PM
That is a sick kaw man. Well done. Simple and clean, with personal touches. Thats a true back alley build! :cheersmate:

79DeathMachine
12-01-2011, 8:03 PM
What are you using for switches for your mini turns? I have a 79 KZ that was "barn fresh" when I bought it and the wiring is a mess. I think the turn switch is fubar so im thinking on starting from scratch.

sfos
12-01-2011, 9:18 PM
Badass man. My kinda bike. Simple and oldschool

fredd7924
12-01-2011, 9:34 PM
What are you using for switches for your mini turns? I have a 79 KZ that was "barn fresh" when I bought it and the wiring is a mess. I think the turn switch is fubar so im thinking on starting from scratch.

I am using a basic single pole dual throw toggle switch (just a on / off / on switch). I have it mounted below the gas tank, so its off the handlebars. I think you can pick them up at radio shack for a couple bucks.
http://www.go2marine.com/docs/8/1/4/8/81481F-p.jpg

Iron13
12-02-2011, 7:52 PM
The Ammo box idea came out great. Sweet ride dude.:cheersmate:

trc87
10-16-2012, 12:25 PM
Man, that looks great! I am using the TC bros axle plates and some tubing I bent myself to bob my KZ. One problem I am having is the left side axle plate. The slot for the rear hub coupling sleeve is just a tiny bit narrow. The coupling sleeve won't fit through it. Did you have to make yours a bit taller too? If so, how did you do it. I know I could just go at it with a cutting disc and grind it out, but I want it to look good, and I'm afraid the result would be a bit sloppy. Thanks!

interstatejoe
10-16-2012, 1:09 PM
Great build. I've never seen an ammo can that small. Did you modify it to make it smaller?

trc87
10-16-2012, 3:14 PM
Yeah, he cut a chunk out of the middle of the can, and a chunk out of the lid the the same size. It is actually a simple solution and it looks great!

fredd7924
03-06-2013, 6:56 PM
Man, that looks great! I am using the TC bros axle plates and some tubing I bent myself to bob my KZ. One problem I am having is the left side axle plate. The slot for the rear hub coupling sleeve is just a tiny bit narrow. The coupling sleeve won't fit through it. Did you have to make yours a bit taller too? If so, how did you do it. I know I could just go at it with a cutting disc and grind it out, but I want it to look good, and I'm afraid the result would be a bit sloppy. Thanks!

I should have mentioned it on an earlier page, but I did have to notch the left axle plate to fit the hub coupler. I just used a Dremmel and made a bunch of slow / light passes like mini end mill.


To answer someone else s question earlier about how I made the ammo box....I took two strips of masking tape all the way around the box with the lid, making sure they were completely parallel. I then removed the lid and continued the tape around. I used the tape as a reference line when cutting both the box and lid then.

I did not use the latch because it would have interfered with the frame, so instead I just squished the lid a little bit to create an interference fit.

moroun
03-06-2013, 10:10 PM
Super impressed. As basic as this build is...very inspiring for what you spent and the end result.
P.s. FUCK the police! They just mad cuz you ain't brown!

Jetblack
03-06-2013, 10:50 PM
Nice one man, making do with what you have and making it work well, is an art form.

NeonDave
03-18-2013, 12:39 PM
Thats a sweet bike ya got there its nice to see alot of awesome bikes coming out of pa to cant wait for spring time to hit the road.

hollywood86
08-04-2014, 5:38 PM
love the idea of the license plate chain guard and the hidden signal lights? did the police tell you anything because you didnt have front signal lights??? i only ask because i just got my kz and it doesnt have the front turn signals or a turn signal swith to top it off. lol

Deadlastkz400
08-13-2015, 12:36 PM
Nice build. That tank looks sick! Did you have to modify it at all to get it on there? I have a buddy with a spare sporty tank I am looking at throwing on my kz400 bobber.

Freewheeler
08-15-2015, 8:50 AM
Great job - I liked your approach to hardtailing it (your welding skills put mine to shame!).

Nick

hoochiecooochie
12-08-2015, 10:32 AM
Did you cut the pipes from the Hardtail Kit?
I am currently working on the exact same project, but don't want to make it this low.
Wondering if the pipes are long enough.

Currently living in the Netherlands, and considering buying the kit from TCBros as well.
Which makes it a little more expensive for me. Hopefully worth it.

One hell of a bike by the way. Great build.

Duttry98
12-08-2015, 7:00 PM
Damn Man, I don't know what's slicker...., the bike or the Camaro. Both look great!