1980 Kawasaki KZ440 Cafe Racer "NONAMETHOUGHTOFYET"

CrazySteve911

Need Bigger Tires
Location
Loris, SC
1980 Kawasaki KZ440 Cafe Racer "Mumford"

So, a couple of weeks ago purchased my new project. This beut of a cycle.
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A 1980 Kawasaki KZ440, with only 7228 miles. It came with a 1983 Kawasaki KZ550 also, both for 700 bucks and both titled. I gave my stepdad the 550, and hes currently making a bobber/rat rod out of it. Already has it hardtailed and everything.My plan for the KZ440 though is to cafe the bad boy out. Strip it naked, cover the essentials, smaller gauges, headlight lowered, lowered bars, smaller seat, relocate battery and wires for a more naked look, and drop as much weight as possible. Bike weighs in at exactly 400 pounds, and im hoping to lose 30 or so pounds, but its looking more like 20ish. Going for a khaki color on the tank and side covers, and khaki exhaust wrap, and hoping to get a local shop to fab me up a dark brown seat. we'll see how that goes. Most people nowadays get huge 750+ motorcycles and cafe them, and i don't think that's what a cafe is. They're meant to be light, fast, and small. So this twin will do just fine i hope ahaha. The fella i bought it from said it was running last summer, but the generator gasket was leaking, and he couldn't get the bolts off to switch out the gasket so it was just sitting in his garage since late last summer. Soon as I brought it home I ordered the entire engine gasket set, just in case, and easily got the bolts out and switched the gasket and put oil back in. Haven't tried starting it yet, as my battery charger broke a couple of days before this, so until i can find another charger, i did a few cosmetic changes.You cab see in the pictures me trying to make the charger work, but its just been through too much ahaha. This weekend and next week ill take the carbs off and clean them out and see if this bad boy runs yet. My goal is to have it completely finished by May 18th, as that's bike week in good ole Myrtle Beach, SC. Heres whats been done so far. I stripped the seat, tank, side covers off, only to discover the thickest wiring harness the world has ever seen EVER. The longest part of this project is going to be dewiring it to a more of a bare bones, everything you need, nothing you don't.

So, this is it in its nakedish form, when i replaced the gasket.

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After the gasket was set in, I went ahead and started working on the tank. I took the emblems out, bondoed the holes where they were at, sanded her down, and painted her the only color i know. KHAKI.

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Then did the same to side covers, and flipped the handlebars upside down to see if they were as low and the angle I wanted. They aren't so it looks like new bars are gonna be on the list. Cant decide between clubmans or clip ons. Clip ons will be lower, more adjustable, and a cleaner look, but clubmans are cheaper. lol.

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Clear coated the tank, lowered the front fender, and gonna chop it off on each end for a smaller look. Thing was huge, and gonna prime it and paint it black by next week. And p.s, my garage looks like its full, but its the size of a small shop. My stepdad just outcasted me to this corner of it.

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As of right now im waiting for some KCCO stickers to come in to put either on the tank or the side covers, gonna machine a KCCO plate for the front forks where a KAWASAKI plate was, gonna chop the fender up, try to dewire some of the wires, and cut part of the seat frame out, right behind the rear shocks. Was thinking of getting some pinup girl decals on him, but havent decided if I want those yet. I'm still really in the planning phase. Trying to decide on which parts I want. I have a general idea of how I want the bike to come out, but just havent decided on a few things. Heres what I want the front end of the bike to look like.

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GPD605X

Lockers Installed
Founding Member
Location
Gulfport, MS
Very nice! I've got an 81 Suzuki GS450S and I need to work on my carbs and get it running. Of course, I have no mechanical knowledge of bikes.
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GPD605X

Lockers Installed
Founding Member
Location
Gulfport, MS
I've only had mine for about a month maybe. The guy I bought it from said he let it sit for about a year but was running great when he drove it. I'm trying to find a local guy to see if he could help me out with taking the carbs off and cleaning them and get it running again. I need to make/buy a new seat, the guy kind of made it so it's in pretty rough shape. And of course, I drained the gas tank and left the lid off for a day and now there's rust in the tank, so I have to coat the tank.
 
S

Steeze

Guest
Nice!

I've built 6 cafe racers in the last 2 years... they're fun and profitable for sure.

Go with the clubmans or swap modern forks on there. Ninja forks will work with a little modification then you can run clipons
 

CrazySteve911

Need Bigger Tires
Location
Loris, SC
Yeah, I'ma treat him as a DD, or at least drive it as much as possible.

And Steeze, i'm actually getting a new headlight bracket that opens up the possibility of clip ons on the stock forks. And not gonna lie, seeing your Cafe's is partially what made me want to do this.
 

CrazySteve911

Need Bigger Tires
Location
Loris, SC
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Got the stickers for the tank today, putting them on tomorrow. Chopped up the fender and painted it black, most likely gonna scrap it and buy a different one or just go no fender, as it wont go any lower than it does due to its dumb mounts. Why.

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And did some wiring today. Got rid of the horn, and the neutral, oil, and light that shows when you're braking. Still have a lot to go through, and im super glad that it all runs off the headlight. Thats my FAVORITEPARTEVER.

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CrazySteve911

Need Bigger Tires
Location
Loris, SC
I'm a night owl and it was a super nice night tonight, so decided to go out to the 'rage and work on the bike some. Got the stickers on ever so perfectly, and cleaned up the engine a little bit. Tomorrow, once i get some more grinding wheels, i'm going to cut off some of the rear end, and cut off the muffler to make way for the smaller one i'm going to order soon. I would like to straight pipe it just how it will be, with no muffler, since i live in an inspection free state, but i've heard its not the best for the engine if its a DD. Any other thoughts on that?

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CrazySteve911

Need Bigger Tires
Location
Loris, SC
Alright. Successful cafe day. Chopped the rear, straight piped it for now, and dug hard into the wiring.

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Had fun with ripping out some wires. Got all the gauges removed and wires labeled.

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The bulk of the wiring was in the headlight bucket. Since I am going to get a slimmer headlight, I'd like to get as much of the wiring in this little triangle space as much as possible. It's under the gas tank so its bueno.

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And chopped a good foot or so off the rear end.

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I'm going to a concert tomorrow in Georgia, and then work Friday and Saturday, so hopefully ill be able to take the carbs off Sunday and get them cleaned up and whatnot.

I've got some rear adjustable shocks for the rear that I may put on. Havent decided yet if i want them.
 

GPD605X

Lockers Installed
Founding Member
Location
Gulfport, MS
very nice... I finally found a local guy to work on mine and he's just right down the street! hopefully I'll get it to him this weekend!
 

CrazySteve911

Need Bigger Tires
Location
Loris, SC
Dude so many decisions. I think I'm going to roll with this seat for this season, and then find a seat pan I like, if I don't like how this seat turns out. I also need to fab up someway to mount the new battery I'll be getting.
 

CrazySteve911

Need Bigger Tires
Location
Loris, SC
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Decided to put the adjustable shocks on. I like them a little bit more and they're much stiffer, but they're on the highest setting so I can loosen them up if my butt can't take it.
 

CrazySteve911

Need Bigger Tires
Location
Loris, SC
Wheeled him out today for the sunshine right before I pulled the carbs. Ordered my clubmans, hopefully in by the end of the week. Getting closer everyday!


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Gonna fab a brakelight/license plate holder right underneath the seat, where I got the rear end off. To cover that huge hole, and those nasty cuts. Need all the gauges, grips, lights, just gotta find the styles i want. Gah I love this thing.
 

CrazySteve911

Need Bigger Tires
Location
Loris, SC
I reworked another fender, I like this one a lot more and it was easier to lower it. Love how it looks. Painted the engine a flat black. Put the original headlight back on after some modding and painting, ill work with it for now until I find an aftermarket one I enjoy. Dropped the seat off at a local upholsterer Wednesday, and he said itll be ready by end of next week. I'm going to order a carb jet kit by early next week and whenever I get that see how this baby runs. Definitely going to do some custom exhaust. You guys should post up some unique exhaust youve seen on some bikes so i can get an idea. Doesnt matter how crazy it is, I've got enough pipe to do just about anything ahaha All I need to do is order gauges, tail light, some minimalist button clusters, finish up some wiring, possibly paint the wheels black(?), paint the lower fork black, order the fork boots, FIND SOME FREAKING BROWN GRIPS IF THEY EVEN EXIST,order some shorty levers, find a way to cover the exposed rear/license plate mount, and find a way to mount the battery. Sounds like a lot but really most of it is just getting the part and putting it on ahaha. Deadline is officially end of the month, bike week starts May 9th, and I want to get some riding and fine tuning in before then. CAN'T WAIT. Anyways, ON TO THE PICTURES.


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CrazySteve911

Need Bigger Tires
Location
Loris, SC
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Forgot to post these pictures, picked the seat up last week. Total cost was 75 bucks. Not too bad considering online they're 200+. Pretty happy with it. Its the slightish shade lighter than the fender but thats an easy fix. Waiting on the carb jet kit to get here, and exhaust wrap should be here Fridayish. After that its just gauges and a brakelight and hes good to go! Pretty stoked.
 
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