Project KZ440 Scrambler

I've always been a big scrambler fan. Something about a old school motorcycle with knobby tires just clicks for me.
For this build there were a few prerequisites; Double cradle frame, Two cylinders, 400cc+, Chain/Belt drive, and Japanese.
...Enter the 1982 KZ440D LTD Belt drive.

I paid far too much money for it, it "ran when parked", and it needs a new seat pan(found out after getting it home), buts its mine.

On to the build plans:

Kawasaki Green tank/side covers
Protaper 1-1/8 KX High handlebar
Oversize bar mounts
Custom seat
Kenda K761 tires
Compact handlebar switches
Led tail light
LED Signals

Thats it for now! If anyone have suggestions for aftermarket handlebar switches, and oversize bar mounts I'm all ears.
I'll update this as I work on it. 

 

Plans for an upswept exhaust system?

By the way, I don’t think I have ever seen chrome pipes so dark blue so far back. I hope there is an explanation that does not involve fuel mixtures that were aluminum-melting lean.

TexasKZ wrote:

Plans for an upswept exhaust system?

By the way, I don’t think I have ever seen chrome pipes so dark blue so far back. I hope there is an explanation that does not involve fuel mixtures that were aluminum-melting lean.

I have yet to decide on the exhaust. That will probably be the last thing. 

Also good point about the colour of the exhaust.

What condition is the oil in? Is it full?

 

TexasKZ wrote:

Plans for an upswept exhaust system?

By the way, I don’t think I have ever seen chrome pipes so dark blue so far back. I hope there is an explanation that does not involve fuel mixtures that were aluminum-melting lean.
 

It's an aftermarket exhaust, so I'm hoping the bluing is a style thing and not the result of excessive temperatures.

My first thought was a lot like yours. The airbox is intact, so unless someone changed the jetting significantly it shouldn't be running deathly lean.

Adrian719 wrote:

Thats it for now! If anyone have suggestions for aftermarket handlebar switches, and oversize bar mounts I'm all ears.
I'll update this as I work on it.
 

For the bar mounts...

Remove the existing bar clamp tops. (Looks like you've done this) Get under the top triple clamp and undo the hardware holding the bottom halves of the clamps.
Reassemble the top and bottom halves off the bike, and take those pieces to a machine shop to have them enlarge the hole to 1.125". You're on your own for switches.

Side note: it's a good idea to do a basic assessment - spark quality, compression, valve clearances, etc. - before you get stuck in too far. There's a shop manual here: kzrider.com/modules/ServiceManuals/kz440.pdf
 

Nerdy wrote:

Adrian719 wrote:

Thats it for now! If anyone have suggestions for aftermarket handlebar switches, and oversize bar mounts I'm all ears.
I'll update this as I work on it.

 

For the bar mounts...

Remove the existing bar clamp tops. (Looks like you've done this) Get under the top triple clamp and undo the hardware holding the bottom halves of the clamps.
Reassemble the top and bottom halves off the bike, and take those pieces to a machine shop to have them enlarge the hole to 1.125". You're on your own for switches.

Side note: it's a good idea to do a basic assessment - spark quality, compression, valve clearances, etc. - before you get stuck in too far. There's a shop manual here: kzrider.com/modules/ServiceManuals/kz440.pdf

 

Excellent suggestion on the bar mounts! Also thank you for the link to the service manual!

Welcome to the madness.  I recently started a similar project but it sounds like I started off a lot worse. Slowly sourcing replacement parts and trying to get it safe to ride first…

Good luck with your project. I am curious what you come up with for seat and exhaust. 

Today's find


The front pulley rotates back and forth on the output shaft, I assume its not supposed to do that. 
And there is a splice in the wiring harness near a fuse holder. 
 

The splines on the belt pulley are worn out allowing it to move around on the output shaft, so that's garbage. I guess I will go ahead with the chain conversion now. 
I have been unable to remove the drain plug bolt. Vice grips, big ass channellocks, and even a chisel & hammer. No dice. It's in there good. I'm going to try and drill the whole thing out tomorrow. 

Changes for the build:
Kenda K671 tires 
EMGO 7/8 Street Sport handlebar 
ODI Cush Road Bike grips

Success!!! I got the drain plug bolt out. Had to drill it. 
The engine had 1.5L of oil in it. No metal in the oil or filter.

I pulled the fenders and am going to try to prime & paint them. I also pulled the handlebar switches to try and clean up & paint.

Next step is getting a battery, and trying to start it up. I can only find standard batteries locally in YB12A-A. I want an AGM. 
Does anyone know of another easily available battery size that fits?

Switches are getting cleaned, painted, and refurbished.


Forks done
 


Exhaust is out, 2 studs came out whole, 2 broke off at the nut but came out with vice grips.