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KZ 440 custom bobber project for the wife

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KZ 440 custom bobber project for the wife 12 Jul 2015 01:24 #680477

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While I'm busy with the KZ650, also doing a custom bobber for my wife. This project started last year so decided to add this to this site for progress :)
KZ 650 mono shock rebuild project.
KZ 440 Ltd bobber build for my wife

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KZ 440 custom bobber project for the wife 12 Jul 2015 01:31 #680478

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Roughly in Nov 2014 we were sitting around the dinner table and this project took off. My wife, being a cancer survivor wanted a custom bike. So me and our chapter president got onto the net and found a KZ440 LTD motor for about $40.

How could we do this on a budget?

This was the start of a journey lol!

Will post the photos of the project up to now....
KZ 650 mono shock rebuild project.
KZ 440 Ltd bobber build for my wife

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KZ 440 custom bobber project for the wife 12 Jul 2015 01:56 #680480

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THE CONCEPT


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This was what she had in mind....

THE BUDGET


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hahahahahahaha :)
KZ 650 mono shock rebuild project.
KZ 440 Ltd bobber build for my wife
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KZ 440 custom bobber project for the wife 12 Jul 2015 02:00 #680481

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Motor...check!

Now we needed a frame! www our local ebay version, gumtree and found a CX500 rolling chassis for $100


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and then had to make it fit in our run about car!


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KZ 650 mono shock rebuild project.
KZ 440 Ltd bobber build for my wife
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KZ 440 custom bobber project for the wife 12 Jul 2015 02:04 #680482

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Next step: make it all fit!
Grinder and welding machine...yeah!


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The twirly tubing gave this quite a nice look!!
KZ 650 mono shock rebuild project.
KZ 440 Ltd bobber build for my wife
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KZ 440 custom bobber project for the wife 12 Jul 2015 02:06 #680483

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Mocking up all the bits and pieces!


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Ok, challenge! how to get the left side sprocket drive to connect to a right hand shaft drive :sick:

Thinking......
KZ 650 mono shock rebuild project.
KZ 440 Ltd bobber build for my wife
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KZ 440 custom bobber project for the wife 12 Jul 2015 02:08 #680484

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So in the mean time, let's work on some body panels and fairing etc....


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and more.....


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KZ 650 mono shock rebuild project.
KZ 440 Ltd bobber build for my wife
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KZ 440 custom bobber project for the wife 12 Jul 2015 02:10 #680485

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Custom seat done!

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KZ 650 mono shock rebuild project.
KZ 440 Ltd bobber build for my wife
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KZ 440 custom bobber project for the wife 12 Jul 2015 02:14 #680486

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Chain drive to sprocket drive is not going to be easy! Plan B!


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Replace the Honda shaft drive with bandit rim chain drive and redesign the brackets!
Yesterday we fetched the brackets from the engineering company. We made a cardboard template, then designed it in Inventor, and got them to cut it with a flow jet : Nice!


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KZ 650 mono shock rebuild project.
KZ 440 Ltd bobber build for my wife
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KZ 440 custom bobber project for the wife 12 Jul 2015 02:16 #680487

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My wife in the mean time removed the starter motor, cleaned it and re assembled it...Well done Honey :)
She also attacked the motor, cleaned it and sprayed it with heat resistant silver....looks much better!


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KZ 650 mono shock rebuild project.
KZ 440 Ltd bobber build for my wife
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KZ 440 custom bobber project for the wife 12 Jul 2015 02:19 #680488

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And in the mean time we did some research and found that this was a KZ 440 LTD. It is missing the clutch actuator.
What a mission to find this cover!!! :evil:
So we are stuck....searching searching....


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KZ 650 mono shock rebuild project.
KZ 440 Ltd bobber build for my wife
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KZ 440 custom bobber project for the wife 12 Jul 2015 03:53 #680492

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If you cant find one,you could do an hydraulic conversion. Or on some race bikes,Ive seen homemade (cable operated) shifters. Looks pretty straightforward.
www.kzrider.com/forum/11-projects/594313-csr1000-project-build
CB550 (1978)
CB500/4 (1972)*
KZ1000CSR (1981)
XT 600E (1999)
TDM900 (2003)

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Last edit: by davido.
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