KZ440 Scrambler(ish) Build | GTAMotorcycle.com

KZ440 Scrambler(ish) Build

A

Adrian719

Well-known member
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(possibly fenders)
Custom seat
EMGO 7/8 Street Sport handlebar
Knobbies
Led tail light
LED SignalsPXL_20240413_212248387~2-min.jpgPXL_20240413_215958512-min.jpg
 
Last edited:
So while this bike is fairly clean for its age, it definitely has some small problems:

First off was the oil drain plug. It was stripped. A hammered on socket didnt work, 16" channel locks didn't work, and vice grips didnt work. I ended up drilling it out. The engine only had 1.5L of oil, half of its 2.9L capacity.

The front belt pulley was loose on the output shaft so its splines were worn down(loose nut). Thankfully I plan on doing a chain conversion anyways.

The airbox filter box is broken, and apparently these things really don't like to run without a proper airbox, but I have plans for that.

The seat pan is rusted out, so it's garbage. Unfortunately there are no other model seat pans that fit so I need to find one on ebay or make one.

Lastly the carbureter needs new diaphragms. There are a couple of sources for around $40 a piece.
 
I ended up "refurbishing" the gauge cluster. I took everything apart and cleaned it all. Repainted the outside, replace the seals, and cleaned the glass. The faded faces are staying.
PXL_20240420_195237029-min.jpg

I also painted the forks and added gaiters.
PXL_20240419_220941042-min.jpg

I was planning on replacing the handlebar switches, but decided to refurbish them instead. Stripped them down, cleaned & lubricated everything, and put them back together. I haven't gotten a pic of them re-assembled as I'm waiting on the new handlebar. PXL_20240419_145520314-min.jpg
 
Sounds like a fun project.
 
TK4 said:
You're t*rd polishing.
Click to expand...
A build like this is for fun, forget about dollars and sense. I learned that a long time ago… boats, bikes, cars… hard way to make money.

Think about it… a set of crusty laced rims and a set of duals port tires will cost $600 or more. Sad thing is adding tires and rims only makes the bike with $500.
 
Mad Mike said:
A build like this is for fun, forget about dollars and sense. I learned that a long time ago… boats, bikes, cars… hard way to make money.

Think about it… a set of crusty laced rims and a set of duals port tires will cost $600 or more. Sad thing is adding tires and rims only makes the bike with $500.
Click to expand...
Exactly. This isn't a build to sell for a profit. It's for something to do in my spare time for fun. So far I'm in it like $200 for paint and parts lol. The most expensive thing will be tires.
 
Did you take those forks apart or just paint them. Good chance the original fork oil is still in there only now it's turned into a silver tinted soup. Draining and replacing with fresh would help but a complete disassemble and rebuild would be best.

If your plan is just to freshen things up with paint, well that can be a lot of fun and there's nothing wrong with that (most of us have scooted down that road at least once) but then of course @TK4 post #7 becomes valid.
 
timtune said:
Did you take those forks apart or just paint them. Good chance the original fork oil is still in there only now it's turned into a silver tinted soup. Draining and replacing with fresh would help but a complete disassemble and rebuild would be best.

If your plan is just to freshen things up with paint, well that can be a lot of fun and there's nothing wrong with that (most of us have scooted down that road at least once) but then of course @TK4 post #7 becomes valid.
Click to expand...
Fresh oil, new seals. No replaceable bushings in these forks.
 
Excellant. Was I correct about the silver soup?
 
You must log in or register to reply here.

Back
Top Bottom