My build thread - KZ440 - Page 3

ontwo · 07-13-2010, 11:06 AM

Thanks Dave. Just got TWF back from being blocked at work.

Dave · 07-14-2010, 04:29 PM

Quote:

Originally Posted by ontwo

Thanks Dave. Just got TWF back from being blocked at work.

I read this wrong. Def just went back in the thread thinking "wtf did I do now?"

ontwo · 07-14-2010, 04:46 PM

Still waiting on the damn oil seal. Gonna start cleaning out the tank tonight. May start fabbing the seat. Just ordered a leather stitching awl

ontwo · 07-17-2010, 10:57 PM

Ok. A bit of an update. Still waiting on the oil seal. Here is why

Got the pin back in the crankshaft that seats in the backof the timing mechanism. It was sheared off. This is how it looked when I took the timing mech off

It took me the longest to drill out the old pin to make room for the new one.

I started on my seat. Not sure if I'm gonna stick with this one or start over.

Metal for the seat.

Camping foam

Here are tools I used to shape the seat

Waiting on the adhesive to set

Also worked on the cracked intake boots

More to come...as soon as the oil seal gets here.

Gas Man · 07-18-2010, 03:31 PM

Keep going

ontwo · 07-18-2010, 05:48 PM

Just realized that I have no rectifier. I'll probably get a new one from Oregon Motorcycle Parts. They come highly recommended at the Kawasaki Twin Owners Forum. I'll let you know how it goes.

Dnyce · 07-19-2010, 08:29 AM

id say skip the filters and go with velocity stacks, and new rubbers(theyre cheap)

each time i built my kz, ebay and bikebandit were my friends

have fun!

whats u plannin on doin to the gs?

ontwo · 07-19-2010, 09:30 AM

Quote:

Originally Posted by Dnyce

id say skip the filters and go with velocity stacks, and new rubbers(theyre cheap)

each time i built my kz, ebay and bikebandit were my friends

have fun!

whats u plannin on doin to the gs?

Good ideas. But right now I'm going real cheap. I might add those later.

As for the GS, not sure. I may just get it running and unload it. I figure I can get rid of it easier if it is running. Also, I've got a clean title. That should help.

ontwo · 07-21-2010, 12:27 AM

Update.... Tonight we cooked out. After, dad and I started tinkering. We got the new oil seal in, tming mechanism on, points plate back on. Then new oil filter, filled it with oil. Reinstalled the carbs, put the tank on, hooked up the fuel line and vacuum line.

Turned on the switch, hit the button, and.....NOTHING. About that time, dad and mom had to go, my daughter wanted to play wii, so we stopped.

After some wii golf, bowling and boxing. Then some fairy tales and Spongebob book. I headed back out.

Ok, maybe we didn't line up the timing mechanism correctly? Nope, nothing. Maybe it has a clutch swich? I took the clutch cover off. Everything looked fine.

Just when I was about to go in for the night, I looked down. A lead from the starter relay was not connected. It matched the color of the wire beside it with the female connector. So WTF? it can't hurt. I plugged it in and......

SHE IS RUNNING!!!!!!!!!!!!!!!!!!!!!!!!!!!!!

So this means that the fun will now begin. Tomorrow, my wife, daughter and I leave for Gatlinburg for a few days. After that, Ms. KZ has an appointment with the sawzall.

Stay tuned........

ontwo · 07-31-2010, 01:11 AM

Update...

What a night. Last night I began the teardown. Getting her naked and left with a pile of parts.

Dropped her to 7" and leveled her up with some lumber

Swingarm off. Ready to SAWWWWWWWW

The aftermath

Swingarm back on

Sat the tank back on to look at something that has been bothering me....

If I use the stock tank (which I plan on), there is not going to be enough room for my seat and the battery box and electrical box at stock length.

So I've decided to stretch it some. I've got my tubing coming on Monday. I plan on making my jig to keep the alignment. (I was planning on using the swingarm). But I really think I will like it better with a stretch. It will just take a little more work. Stay tuned

07-13-2010, 11:06 AM	#21
ontwo Designated Drinker Join Date: Jul 2008 Location: shitville Moto: 2009 ZX6R Posts: 1,661	Thanks Dave. Just got TWF back from being blocked at work. __________________

07-14-2010, 04:46 PM	#23
ontwo Designated Drinker Join Date: Jul 2008 Location: shitville Moto: 2009 ZX6R Posts: 1,661	Still waiting on the damn oil seal. Gonna start cleaning out the tank tonight. May start fabbing the seat. Just ordered a leather stitching awl __________________

07-17-2010, 10:57 PM	#24
ontwo Designated Drinker Join Date: Jul 2008 Location: shitville Moto: 2009 ZX6R Posts: 1,661	Ok. A bit of an update. Still waiting on the oil seal. Here is why Got the pin back in the crankshaft that seats in the backof the timing mechanism. It was sheared off. This is how it looked when I took the timing mech off It took me the longest to drill out the old pin to make room for the new one. I started on my seat. Not sure if I'm gonna stick with this one or start over. Metal for the seat. Camping foam Here are tools I used to shape the seat Waiting on the adhesive to set Also worked on the cracked intake boots More to come...as soon as the oil seal gets here. __________________

07-18-2010, 03:31 PM	#25
Gas Man Trip's Assistant Join Date: Feb 2008 Location: Imported from Detroit Moto: 2009 HD Street Classic Posts: 12,149	Keep going __________________ -Chris "Why pay somebody else to fuck up your bike?" Run Amsoil Product

07-18-2010, 05:48 PM	#26
ontwo Designated Drinker Join Date: Jul 2008 Location: shitville Moto: 2009 ZX6R Posts: 1,661	Just realized that I have no rectifier. I'll probably get a new one from Oregon Motorcycle Parts. They come highly recommended at the Kawasaki Twin Owners Forum. I'll let you know how it goes. __________________

07-19-2010, 08:29 AM	#27
Dnyce flyin high Join Date: Mar 2008 Location: cali Moto: 10speed huffy w/cards in the spokes Posts: 2,318	id say skip the filters and go with velocity stacks, and new rubbers(theyre cheap) each time i built my kz, ebay and bikebandit were my friends have fun! whats u plannin on doin to the gs? __________________ "Racing Is Life, Everything Before and After is Just Waiting" Steve McQueen

07-21-2010, 12:27 AM	#29
ontwo Designated Drinker Join Date: Jul 2008 Location: shitville Moto: 2009 ZX6R Posts: 1,661	Update.... Tonight we cooked out. After, dad and I started tinkering. We got the new oil seal in, tming mechanism on, points plate back on. Then new oil filter, filled it with oil. Reinstalled the carbs, put the tank on, hooked up the fuel line and vacuum line. Turned on the switch, hit the button, and.....NOTHING. About that time, dad and mom had to go, my daughter wanted to play wii, so we stopped. After some wii golf, bowling and boxing. Then some fairy tales and Spongebob book. I headed back out. Ok, maybe we didn't line up the timing mechanism correctly? Nope, nothing. Maybe it has a clutch swich? I took the clutch cover off. Everything looked fine. Just when I was about to go in for the night, I looked down. A lead from the starter relay was not connected. It matched the color of the wire beside it with the female connector. So WTF? it can't hurt. I plugged it in and...... SHE IS RUNNING!!!!!!!!!!!!!!!!!!!!!!!!!!!!! So this means that the fun will now begin. Tomorrow, my wife, daughter and I leave for Gatlinburg for a few days. After that, Ms. KZ has an appointment with the sawzall. Stay tuned........ __________________

07-31-2010, 01:11 AM	#30
ontwo Designated Drinker Join Date: Jul 2008 Location: shitville Moto: 2009 ZX6R Posts: 1,661	Update... What a night. Last night I began the teardown. Getting her naked and left with a pile of parts. Dropped her to 7" and leveled her up with some lumber Swingarm off. Ready to SAWWWWWWWW The aftermath Swingarm back on Sat the tank back on to look at something that has been bothering me.... If I use the stock tank (which I plan on), there is not going to be enough room for my seat and the battery box and electrical box at stock length. So I've decided to stretch it some. I've got my tubing coming on Monday. I plan on making my jig to keep the alignment. (I was planning on using the swingarm). But I really think I will like it better with a stretch. It will just take a little more work. Stay tuned __________________