1976 KZ400 Cafe Racer Project (Advice Appreciated)

Hey all, long time lurker and figured it was time to post up what I'm working on. Bought my first bike, a kz400 cafe racer project, off ebay for $232 (from the nicest guy) and picked her up in April. I tried to pick a project that had a lot of the "big ticket" custom bits completed as my technical skills are limited. Worked diligently on the bike throughout the summer but I had to head back to school in September so I have to postpone working on it till winter break.

How I received the bike + What I am currently in the process of modifying



What I've done to this point:

- I bought 33mm clip-on handlebars (replacing the inverted xs650? handlebars the previous owner had installed) allowing for me to shave the old handlebar clamps off of the top of the triple tree clamp (which I then polished). I bought replacement headlight clamps for the stock headlight ears and replaced the headlight entirely (melted it when stripping). Its now a chrome bates style headlight with a switch on top and an amber lense. I have since purchased fork gaitors/boots too since I like that particular look. I plan on making the forks stick through the top triple tree/yoke clamp about 1-1.5 inches because 1) I like the look, I think it will level out the custom speedo mount with the top of the triple tree, and I feel like it gives the bike a more agressive stance.

- I removed the old tires / tubes (at home with snips lol), bought a new spoke kit from Taiwan (thanks to DTT member "Finnegan" for the advice), stripped and polished each hub, drum, etc and relaced each rim to the best of my ability (both need to be trued). Replacing the stock tires with Shinko 712's (100/90/18 Front, 110/90/18 Rear) and new tubes (yet to do so)

- Took off all the engine covers (breather, clutch casing, starter motor cover, etc, etc) and stripped, sanded and polished them all (Starting to get the hang of polishing). Same for the brakes, master cylinder, handlebar controls/levers, petcock, chain tensioner, etc, etc, basically anything that can be stripped, sanded, polished i'm polishing). Bought all new hardware throughout to match.

- Cleaned up the headers (first put them in a rust remover, then wirewheeled the isht out of them). I bought black header wrap but I still wanted to clean them up prior). Turned out pretty good, I also got a good deal on emgo dunstall style shorty Mufflers.

- Everything the previous owner custom made looks amazing and I really want to commend him on his work. He created the:

1) custom rear cowl from an old harley fender (even went so far as to "french" in a custom taillight)
2) relocated the ignition to the lower frame (Above where the kick stand is)
3) designed the custom 2-into-1 rammed air-esque carb boots/air filter
4) added the unique speedo mount (attached to frame in front of tank)
5) chose the peanut tank / added the required mounts..

Only additions/changes I need to make to these include:

1) fixing the slight gap in the speedo casing created by cutting the original mount to allow for the guage to sit at 90 degrees instead of the stock 60? or so degree location.

2) Creating a side cover for the right side to match the one surrounding the ignition on the left

3) Reinforcing the rear loop (pics below in red)

4) I ruined his 2 into 1 air filter conversion's bondo job when stripping it so I need to rebondo that he did such a nice job I thought it was all metal lol, silly. But I did buy a K&N filter cleaner kit and cleaned up the air filter he had currently installed (cleaned up well)

What I plan on doing:

In hindsight I should've got the bike running first but I did pick up a second engine and I'm excited to try to figure all that out. I bought a new wiring harness too.

- Create / weld a rear hoop under the rear cowl; I think the way it setup could be fine, but I fear that with the battery going under there and whatnot, I would prefer something a bit more rigid. Also, I think that having something like this:



Would really add to the flow that it currently has going.

- Drill a pattern into the rotor (adds to the sportbike look)

- Change Gaskets, Brake Pads, Fork Seals, etc

- Strip Frame Further

- Add Rearsets

- Powdercoating (Tank, Frame, Handlebars, speedo casing, etc, etc)


So far My costs are as follows:

1976 Kawasaki Kz400 Bike (Purchased for $233)
Header wrap – Matte Black (Purchased for $23 Shipped)
Headlight Brackets – Chrome (Purchased for $18 Shipped)
Fork Boots – Matte Black (Purchased for $25 Shipped
Grips – Matte Black (Purchased for $25 Shipped)
Helmet – Gloss Black (Purchased for $75 Picked Up) + Chrome Visor (Purchased for $30 Shipped)
33mm Clip-on Handlebars – Matte Black (Purchased for $28 Shipped)
Wiring Harness (Purchased for $32 Shipped)
Wheels – Shinko 712’s (100/90/18 Front, 110/90/18 Back) (Purchased for $94 Shipped)
Extras: Engine, Tank, Turn Signals, Side Covers, Etc (Purchased for $100 picked up)
Motorcycle Jack ( $50 Picked Up)
Gasket Kit: $65 Shipped
New Spokes: $100 Shipped
New Chrome Headlight: $17 Shipped
Exhaust: $75 Shipped
CRG Bar End Mirrors: $65 Shipped
Turn Signals (4, Chrome, Harley): $60
License Plate: $25
New Bolt Kit: $25

Current Total: $1100


Still need:

Battery
Chain
Tire Tubes
Tires Trued/Mounted
Rearsets
Engine Re-bored + New Pistons, etc
Upholstered Seat
Paint
etc

You Made it this far! You Deserve Photos :

Frame (Current State of Bike)


Parts to Paint and/or Powdercoat


Some Polished / Finished Pieces









"After" Rim


"Before" Rim


Re-Spoked Rims:


"Before" Triple Tree Top Yoke


"After" Triple Tree Top Yoke


New to all of this, let me know what you think Any Advice / Guidance is always appreciated

Adam

How about steering stem bearings,swing arm bushings and other general maintenance.
All the shiney stuff is fine and dandy but worthless if it doesn't go down the road.
I suggest you aquire a repair/shop manual and read it.
There are to many 'builds' getting posted on the net showcasing the look but not the function.
A motorcycle is far more fun when it's ridden than posed with.

.

Many thanks, exactly the type of advice I was looking for. Pmed

Nebr_Rex wrote: How about steering stem bearings,swing arm bushings and other general maintenance.
All the shiney stuff is fine and dandy but worthless if it doesn't go down the road.
I suggest you aquire a repair/shop manual and read it.
There are to many 'builds' getting posted on the net showcasing the look but not the function.
A motorcycle is far more fun when it's ridden than posed with.

.

Hear, hear!