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KZ 440 custom bobber project for the wife

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12 Jul 2015 01:24 #680477 by RickKZ
KZ 440 custom bobber project for the wife was created by RickKZ
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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12 Jul 2015 01:31 #680478 by RickKZ
Replied by RickKZ on topic KZ 440 custom bobber project for the wife
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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12 Jul 2015 01:56 #680480 by RickKZ
Replied by RickKZ on topic KZ 440 custom bobber project for the wife
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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12 Jul 2015 02:00 #680481 by RickKZ
Replied by RickKZ on topic KZ 440 custom bobber project for the wife
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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12 Jul 2015 02:04 #680482 by RickKZ
Replied by RickKZ on topic KZ 440 custom bobber project for the wife
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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12 Jul 2015 02:06 #680483 by RickKZ
Replied by RickKZ on topic KZ 440 custom bobber project for the wife
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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12 Jul 2015 02:08 #680484 by RickKZ
Replied by RickKZ on topic KZ 440 custom bobber project for the wife
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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12 Jul 2015 02:10 #680485 by RickKZ
Replied by RickKZ on topic KZ 440 custom bobber project for the wife
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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12 Jul 2015 02:14 #680486 by RickKZ
Replied by RickKZ on topic KZ 440 custom bobber project for the wife
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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12 Jul 2015 02:16 - 12 Jul 2015 02:17 #680487 by RickKZ
Replied by RickKZ on topic KZ 440 custom bobber project for the wife
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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Last edit: 12 Jul 2015 02:17 by RickKZ.

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12 Jul 2015 02:19 #680488 by RickKZ
Replied by RickKZ on topic KZ 440 custom bobber project for the wife
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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12 Jul 2015 03:53 - 12 Jul 2015 03:54 #680492 by davido
Replied by davido on topic KZ 440 custom bobber project for the wife
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)
Last edit: 12 Jul 2015 03:54 by davido.

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