Kawasaki KZ440 Resurrection

[Enigma]

A couple of years ago my youngest son started to show interest in riding motorcycles (I ride an old Kawasaki). I told him I'd look for one for him. He's a new rider. We agreed it had to be safe, reliable and somewhat cool. "Right up my alley" I'm thinking.

Enter a 1983 Kawasaki KZ440 LTD D5 into the show. Story and pics to follow.

 

Edited February 25 by Enigma

[Enigma]

Off of Facebook Marketplace. Travelled 2hrs to pick it up with the girlfriend's Ford Focus and trailer. Donor bike included. We try to make it happen lol. 

[Enigma]

Didn't really understand the scope of work when I unloaded it but the seat was flawless, the chrome was 85%. Needed new handle bars. Gas tank looked ok. Everything was straight as far as I could tell. Something I thought I could work with. 

[Enigma]

We'd moved to a new place in March '23. I brought the bike home in April. If I didn't have a new garage this project wasn't happening. Built a bike lift out of scraps, strapped it down and off we went. 

Edited February 25 by Enigma

[airedale]

I love tinkering with vintage motorcycles, can't beat the satisfaction getting an old timer back on the road ship shape and running fine. Good luck with your endeavor and keep posting your progress as you go along.

Taking my bikes on the back roads with a pack rod, finding and fishing small streams is one of my favorite things to do.

Al

[Enigma]

Side notes:

1. The garage sits on wetlands and is 50yds from the river. The mosquitoes were savage in the shop all summer. No amount of fans or smoke could keep them away. 

2. I realized quickly that I did not have the exact factory service manual for this model. I had to go off the '82 model. Not great. And especially not great when it's a digital copy on your phone. 

3. A couple of months into it. Snapped a pic for some reason. Carb work maybe. Looked at it sometime later and knew from that point on it was going to be a struggle of wills. 

 

[Enigma]

We were short a left side bottom cover but had a replacement. We cut the screws on all the lower covers to get them off. Cleaning them sucks. New gaskets and stainless hex bolts all around. Only one pinched wire and one leak. Resolved eventually. 

[Enigma]

Had to rebuild the ignition switch, clean up and touch up the starter clutch. Swapped out the bars. Sorry no pics. 

Edited February 25 by Enigma

[Enigma]

Cleaned and rebuilt the carbs with some new kits and several other donors. Most miserable bike I have ever worked on for taking the carbs on and off. Setting the float level was a chore. Stuff wasn't sealing and sliding like it was supposed too. Finally got it to idle. 

[Enigma]

[Enigma]

Does not and will not take throttle. Fouls plugs daily. The ignition advance was frozen solid. Torched it to get it apart. Clean, hone and reassemble. Unfortunately lost the rub point cushion on each of the weights. Retrofit, renew, hone and run. 

[Enigma]

Kinda like gunsmithing in a way. I think. Small springs and weights, washers etc. Two cylinders to sync. 

 

[Enigma]

She had cruiser bars originally. Swept back "buck horn" bars. Awhile into it I understood why they had given up on it. Clutch for the belt drive was on the right. All the control lengths were off with straight bars. 

 

 

[Enigma]

Front brakes. Pulled it all off. Replaced and repaired hoses and seals as neccessary. Held pressure to the front single disc after flushing. 

 

[Enigma]

4 hours ago, airedale said:

I love tinkering with vintage motorcycles, can't beat the satisfaction getting an old timer back on the road ship shape and running fine. Good luck with your endeavor and keep posting your progress as you go along.

Taking my bikes on the back roads with a pack rod, finding and fishing small streams is one of my favorite things to do.

Al

I took the back pegs off one night. No friggin riders. Solo only. Strap your stuff down and go. He understands. 

[Enigma]

Back to the handle bars for a moment. Since the new bars were "standard" type bars I had to install a shorter front brake line, shorter throttle cable and shorter clutch cable. The new shorter brake line was easy to order. I had a shorter throttle cable on hand that works but it's still probably 1" too long. I ended up cutting the original clutch cable and installed a new barrel on the end that had set screws to secure it. Locktite on the set screws. Works well but I think I may have to shorten it another 1/4" to get more adjustability. 

[Enigma]

The new grips were a hassle. The throttle grip installed ok but the left grip was oversize. Had to wrap the bar to increase the diameter before I could get the grip to adhere. I picked up a new set of mirrors, round, long stem. I thought they were awesome but was overruled by my son. Ended up using the black ones that came with it. 

Edited February 27 by Enigma

[Enigma]

New battery. The new plug wires came from my motorcyle. New spark plugs. All the electrical wiring was checked and in spec from the pickup to the plug. 

[Enigma]

There's always a crossroads in every project. There came a point when I looked at this bike, saw a can full of gas and said "we're going to end this now". All because of the headlight.

I wanted to put in a LED unit. The size was an issue. I needed 6 1/4". Not available as an insert. Had meanwhile repaired the existing bucket only to realize it wasn't original. It was 7". Too big. Ordered a plug and play 6" LED. It took forever to ship. I had to cancel the order. They refunded my money. A week later the headlight shows up at the house. I ended up using it so I ended up calling the vendor and paying him. 

I like it. Fits the bike nice I think. 

Edited February 27 by Enigma

[Enigma]

Turn signals are a work in progress. The hardware that came with the bike was not original. They function as turn signals but I need to replace the fronts with dual filament units for riding lights. 

[GreeneHunter]

Your doing a ice job ! I had a BSA 650 back in the day , spoked wheels and all !

[airedale]

Upgrading the electronics and lighting is probably the thing to do with vintage bikes, you are coming along and look to be doing a good job.

Al

[Enigma]

Picked up a pair of side covers. The plan is to prep and then rattle can the tank and side covers the same color. "Luminous Midnight Red" was the stock color. I'm hoping the badges come off with no hassle. Get the color close. The gas tank cover had to be disassembled, cleaned and rebuilt. The petcock had been replaced but it works.

[Enigma]

Set the valve clearance per the FSM. Tightened every bolt on the bike. Road test.

 

[Enigma]

Side note. My son was tolerant. Pissed but tolerant and waning thin. He titled the bike in his own name. Secured the insurance. We got him a helmet and boots. But I was struggling to get it done.