Category Archives: Motorcycles

KZ400 – ordered additional parts

D2Moto had a pretty dang good say going, so I ordered some more parts for the project bike.

Parts Ordered
Parts Ordered

While I was at it, I also picked up some blink for the Ducati.  In fact, almost 1/2 the order is one set of blingware for the Duc.   It deserves a little attention as well.

RC045-Red

Parts page lists them fo the Monster.  Checked the 1098 and they all LOOK similar.  I know Ducati re-uses parts extensivly so, I’m hoping in this case I’m right, or it’s a $40 error.   In the end, if they don’t fit I know plenty of people around the area that I could sell them to for at or near what I paid.

KZ400 – more thoughts on the Cafe project

Hunting to find info on the missing parts from my bike, I’ve collected a few of these as reference. What I notice in this one, is that my side panels are missing some sort of ‘intake grate (black on this blue bike).
kz400-01

After a lot of work, documented here on VW Vortex.. he’s got one hell of a cool result!

After a lot more work
After a lot more work

Then it starts to look like this.  Very clean.. classy.   I’m still split on going retro-rat or going with super-clean (but I  want to do silver, not perl white).   Decisions.. decisions…

cafe10

Ordering some parts

8d92_1_bI want to get this thing going… and the first step will be to get me some of those clubman bars. Found these, hopefully I did not get douched on the price ($52.00 with shipping), from Oregon.

I’m thinking that I can mount them either up or down, depending on how radical I want to make this thing.

At least I’ve taken the first step, and decided that I am NOT going to ‘restore’ the bike, but instead build my first ever Cafe Racer Replica.  God help me.    At least this will be A LOT less expensive than playing with sports cars, and more mentally challenging than watching Television (gack).

Tonight, I think I’ll really dig into this thing by doing some sanding and bobbing the back fender off.

And a couple more interesting ‘inputs’ on final styling:

This looks so 50's retro cool.
This looks so 50's retro cool.

Check out the tail light and turn signals..  very cool.
Check out the tail light and turn signals.. very cool.

And one more idea for the road:

like the dual exit pipes on the right, red tank and that seat is sweet.
like the dual exit pipes on the right, red tank and that seat is sweet.

KZ400 – some motorbike influances

I’ve been looking at a number of vintage bikes, and some cafe racer bikers. Going to save these for reference, and what about each one I really like. It will be interesting to come back to these articles once I finally finish the bike and see what I was thinking.

Bike 1 – Honda twin

Bike idea 01
Bike idea 01
    Elements I like about this Honda.

  • black painted forks
  • cool custom high routed exhaust. The wrapping adds a nice effect
  • chopped off tail
  • stripped off fenders, front and rear
  • it’s also a parallel twin

Bike 2 – Honda twin

bike idea 2
bike idea 2
    Elements I like about this Honda.

  • black paint with gold pinstripe
  • chrome megaphone exhaust in polished stainless looks cool
  • short bars
  • it still has the fenders but they are minimalist and painted.
  • nice steel braided oil cooler lines
  • painted branding (no cast emblems)

Bike 3 – Honda CR550F

cafe03

    Elements I like about this Honda.

  • red and yellow paint, with black side panels is a nice look.
  • black painted exhaust might be easier to achieve than fixing the pitted stock chrome system
  • again, the bobbed tail

Bike 4 – Honda (looks like an old Silverwing)

cafe04

    Elements I like about this Honda.

  • I was originally considering silver paint for the bike, not sure about the blue stripe.
  • like idea of the painted frame
  • one thing that I really liked is the flat metal cover below the seat, instead of the stock curved piece.

Bike 5 – Norton

cafe05

    Elements I like about this Norton.

  • gloss black paint, and stripe.
  • rubber boots on the forks
  • silver painted forks (I think)
  • color matched hub on the rear brake

Bike 6 – Norton

cafe06

    Elements I like about this Norton.

  • nice custom job
  • modern front inverted forks and brakes
  • cool high-mount megaphone exhaust
  • also looks like a mono-shock rear end, very trick.

Bike 7 – Honda (I think its an old XR400)

cafe07
cafe08

    Not really relevant to my current project but.. cool idea!

  • looks like a dirtbike single converted to a street cafe racer
  • cool chopped rear end

Bike 09 – Kawasaki, maybe?

cafe09

    what’s cool

  • paint, love the flat olive retro-vintage WWII paint scheme
  • site exit mega-can exhaust, in black
  • top mounted bars (no clipons) but sort of inverted looking!
  • front still has fender, not so sure about that..
  • rubber boots on forks

Bike 9

real deal KZ400 cafe
real deal KZ400 cafe
    what’s cool

  • flat black paint. I can do that right now.
  • know official name for those bars, ‘clubmans’ it would be the place to start!

KZ400 closer to running again

It was a dark and stormy night…..

Jen on the KZ400
The amazing KZ400

Somewhere it was, but not here. It was rather warm, and the coolness of my subterranean shop was a blessing. It turned out that I would spend the better part of a weekend in there, wrestling the carburetors into the very tight, very new, KZ900 carb holder boots. Stock KZ400 boots are harder to find than Spanish treasure, so based on information on the KZ400 forums, with a little work, carb holders from it’s newer and larger brother would fit. And fit they did, but just barely.

The primary challenges, beyond having to modify the mounting holes on the carb holders (at $45  EACH that was not an easy decision in itself), was that the carb mouth I.D.’s were the same as the carb holder (boot) O.D.  Obviously.. that is going to make for a tough install.  If you have ever held one of these thick, hard, rubber boots, you’d understand the trepidation that kept this project on my ToDo list for 3 months!

Alas, I finally got motivated enough (gas prices and the fact the 3 week Washington Summer was upon us) to tackle the project last weekend.   Here are some thoughts and photos.     A quick thanks goes out to my 7 year old boy for taking the ‘action’ shots of dad working on the bike.    You’re one in a million, kid!

Now, the size of the carbs is not the whole story. About 2 months prior, with a lot of soap, and pressing with most of my weight, I was able to force the carbs into the rubber boots. That’s where they remained for a long time. The concept being, to stretch them out into a static state that was larger than manufactured size, hopefully making the final install a little easier. And frankly, I think it helped out a lot!

Battlefield recon - before the fray.  Look at how much larger the carb mouth is than the holder
Battlefield recon - before the fray. Look at how much larger the carb mouth is than the holder

What I tried to illustrate in photos, but clearly did not convey, is that even WHEN you get a single carb in the boot, the other carbs mouths is them 1/4″ off-center. The carbs are mounted to a thick aluminum flange. That flange forces the specific spacing of the carburetors. There is not play, no give, so the only thing that could possibly allow the successful installation of the carbs was REALLY forcing in one carb, then trying to pry it off center line while forcing in the other. All while holding up the carb set. If I’d had 4 hands it would likely have still been impossible.

Thinking about decades of home auto repair, I decided to use a not-often employed tactic of taking things further apart, to make it easier to put back together again. Often it’s an access issue, and although it looks like there is a lot of space, I was having one here.

I finally got the grand idea that if I dismounted the carbs from the mounting flange itself, it would be easier to manipulate than the entire carb set. So I set about unscrewing the carbs from the flange. In the end, it was what I needed to do, to get this project moving again.

Carb flange seperated and installed.
Carb flange seperated and installed.

Now, that was still a huge struggle to get the flange shoved into the boots, but I was able to get it done! Victory was at hand!!! Now, what remained was to tighten down the holder flange bolts. In what I was say was a stroke of genius, I had purchased round head Allen set bolts to replace the Philips head screws that, normally used. the heads are actually wider, and flatter, but the big bonus was being able to use an Allen key wrench to tighten them down. The brilliance comes in that I knew I might have try just this to get the carbs mounted, and these bolts were part of my plan.

Tightening down the carb holder mounting bolts
Tightening down the carb holder mounting bolts

I do not think I would have been able to do that with the Philips head, as the holes in the flange I used to access them were off-axis from the mounting bolts. Using a universal headed Allen tool, I was able to tighten down the bolts using the carb mounting holes in the flange.

Now of course, comes another challenge. The carb mounting bolts are THROUGH bolts from the BACK of the flange into the carbs. So, I would once again be working in the very confined space between the flange and the cylinder head.

One carb mounted, screws for last carb visible (near side).
One carb mounted, screws for last carb visible (near side).

Using a very neat tool I picked up at Harbor Freight for $3.00 (small right-angle multi-bit ratcheting wrench) combined with a #2 Phillips bit from another kit, I was able to get the screws that mount the carbs to the flange, tightened down. It took a little while for me to determine exactly what which of the bits were short enough to fit in there, but once that problem was solved, carb #1 was mounted!

As with most mechanical projects where some repetitive work is involved, the subsequent processes generally go much faster. And that was the case here. Viola.. CARB ARE INSTALLED!!!

Carbs Installed!
Carbs Installed!

In the last photo here, I think you can see (I can see it, but I know what I think I see) the degree of stretch required to get the carbs into the boots, and also the off center line mounting of the carbs in the holders themselves.

Final dispossition of the carbs
Final dispossition of the carbs

What remains to be tested:

  • Carb holder to cylinder head seal
  • Carb flange to carb seal
  • Reliability of the carb to holder frictionToday, I plan to get the fuel tank remounted, and if I’m feeling really brave, try to start it up.

    More to follow!

  • Trip to Hurricane Ridge

    Having worked 1/2 the previous night, until 1:00AM, then gettng up again at 7:00 to continue forward with a large development project, I decided to reward my hard work with a little R&R at the top of the Olympic National Park.   My friend Bill had the day off so we decided to meet up north of Poulsbo and ride the 80 miles to Port Angelas.  The final destination, Hurricane Ridge 93 miles from our starting point.

    New Summer riding gear – time to update

    I’ve been riding for years in my trusty First Gear leather. I actually bought it at Laguna Seca during a round of the World Superbikes in 2003. Wow.. that means the gear is in it’s 6th season (just realized that now).

    The jacket has seen an easy 100,000 miles of use, and I think it shows. It’s been a good jacket, and it’s not even close to the end of it’s service life. It’s just dirty and it does not fit me at my ‘new weight’ (something I’m working hard on now.. so it will fit again soon). But I love to ride and the fact the jacket makes me feel like I’m stuffed in a sausage skin.. I either ride without, or not at all and neither are acceptable to me.

    So today, I picked up a jacket I plan to use for the summer, and likely sell (or not sell, I still have my first textile jacket circa 1994 and my first leather jacket circa 1995 in my closet — neither fit me).

    So here is my summer replacement. Shift mesh jacket, with armored crash points and a zip-in windproof liner for when it’s no longer in the 90’s here (sadly that will be here soon).  Price at local bike shop:  $150.

    jacket

    I’ve also started to have trouble with my trusty  WWII  ‘Air Force II’ helmet’s visor.  On it’s 3rd season, it’s no longer staying open.   The helmet still fits and works fine in all other categories.   Now, when I rolled into the bike shop I had not intended to buy a new helmet, but it was also not totally out of my mind.     First thing I noticed were some new KBC’s (same brand as the one I’m having an issue with..  but really after 3 years for the price, it’s mostly a NON-ISSUE).   Over the years I’ve thought I might buy a helmet to ‘match’ my bike.  But hardly anyone carries yellow helmets.   This shop had 3.  2 in the new ‘Nuclear Accident’ style (for lack of better term), and they looked great with a big yellow ‘Nuclear’ symbol on the sides.

    After spending about 1 hour with a very cute girl, helping me find a good fitting textile mesh style jacket, I was back at the helmets.  Then I noticed one at the bottom, also in yellow, with a kick-ass skull on the side.  LOL.    So.. that was added to my shopping cart.     It’s SNELL and DOT approved.  Why not..  I don’t know that I’d use if for track days (my Shoei will likely remain in service there) but for street use where SNELL is a more relevant rating.. why not?   SNELL, unlike DOT is not a self-certifying authority, so I feel confident it’s safe for my head. Price at local bike shop:  $140.

    helmet

    So, starting of the new ‘season’ with some updated gear.  I still need to get my leather riding pants repaired…  but I’ll get to that on a rainy day.

    Looks like spring is finally here!!

    It’s about time.  Sunny skies all weekend, temps broke into the 70’s (pretty good for us on most any day!).   For me, it was a weekend of busy work around the house, husting kids around too and fro….  but.. I did mange to squeeze in a nice ride before the weekend was out.  An BOY was it worth it!

    Bremerton 7:00PM

    Rolled out of the garage, topped off the tank (1.9 gallons of high-test) and pointed west.  At this time of year, the sun is starting to say up well into the evening, leaving decent enough light for riding, even with a motorcycle headlamp, until at least 9:00PM.  This left me 2 hours of fun.

    About 1/3 of the way into my ride, I was pleased to discover that Bear Creak – Dewatto Road was once again open.  The storms of 2007/2008 knocked it out (along with a number of other roads), and it had been closed all summer.  It’s a fine little ribbon with little to no traffic.   It’s also provides some very nice views of the Olympic Mountains as you meander along the ridge, once you get there.

    Looking West towards Olympic National Park
    Looking West towards Olympic National Park

    There are not many places along the road to stop, and some of the best vistas are simply too dangerous to stop and photograph (unless you like being run down by a random pickup truck).   I was able to stop and snap this photo at the intersection of Bear Creek and Tahuya-Blacksmith.

    Olympics at sunset.
    Olympics at sunset.

    One last photo, from the same location.   That neat little ribbon of road, and at least to me, a bit of the isolating sense of being out in this part of the county.

    27 miles West of town.
    27 miles West of town.

    It’s days like these that I’m happy to live out here, on the edge of the ‘civilization’ as some would call it.  Great pieces of road, hardly offended by slow movers or Sherriff’s sniping with RADAR for tickets.   Just a man, a machine and some free time.   This is one of those incredible joys that makes my life so special to me.

    I can feel the darkness of winter finally melting away.

    Why bikers wave

    I do not know the origin of this missive, but it’s nice little read, about why motorcycle riders wave at each other.   I’ve always had my own reasons, and they happen to be in 100% alignment with this prose.

    Thanks to ‘Shrek X’ on PNWRiders.com for posting this:

    The bike’s passenger seat swept up just enough that I could see over my father’s shoulders. That seat was my throne. My dad and I travelled many backroads together…searching for the ones we had never found before. Travelling these roads just to see where they went. Never in a rush, just be home by supper.

    I remember wandering down a backroad with my father, sitting on my throne watching the trees whiz by, feeling the rumble of our bike beneath us like a giant contented cat. A motorcycle came over a hill towards us and as it went by, my father threw up his clutch hand and gave a little wave. The other bike waved back with the same friendly swing of his left wrist.

    I tapped my dad on the shoulder, which was our signal that I wanted to say something. He cocked his head back slightly while keeping his eyes ahead…

    I yelled, “Did you know him?”

    “What?”

    “You waved at him…who was that?”

    “I don’t know. Just another guy on a bike….so I waved.”

    “How come?”

    “You just do…it’s important.”

    Later, when we had stopped for ice cream, I asked him why it was so important to wave to other bikers. My dad tried to explain how the wave demonstrated comradeship and a mutual understanding of what it was to enjoy riding a motorcycle. He looked for the words to describe how almost all bikers struggled with the same things like cold, rain, heat, wind, and drivers who didn’t see them, but how riding remained an almost pure pleasure.

    I was young then and I am not sure that I really understood what he was trying to get across, but it was a beginning of something. Afterwards, I always waved along with my dad whenever we passed other bikes.

    I remember one cold October morning when the clouds were heavy and dark, giving us another clue that winter was heading in from just over the horizon. My dad and I were warm inside our car as we headed to a friends house. Rounding a corner, we saw a motorcycle parked on the shoulder of the road. Past the bike, we saw the rider walking thru the ditch, scouring along thru the tall grass, crowned with a touch of frost. Dad pulled over and backed up to where the bike stood.

    I asked Dad…”Who’s that?”

    “Don’t know” he replied…”but he seems to have lost something. Maybe we can give him a hand.”

    We left the car and wandered thru the tall grass ditch to the biker. He said that he had been pulling on his gloves as he rode, and that he had lost one. The three of us spent some time combing the ditch, but all we found were empty cans and bottles.

    My dad then turned and headed back to the car and opened the trunk. He rummaged thru various tools, oil containers, and this and that until he found an old pair of crumpled up leather gloves. He continued looking until he found an old catalogue. I understood what he was doing with the gloves….but I had no idea what he needed with the catalogue.

    “Here’s some gloves for you” my dad said as he handed them to the rider…”and I brought you a catalogue as well.”

    “Thanks”..I really appreciate it.” He reached into his hip pocket and pulled out an old chain wallet.

    “Lemme give you some money for the gloves” he said.

    “No thanx” dad replied as he handed them to the rider. “They’re not worth anything and they’re old anyway”.

    The biker smiled. “Thanx alot.”

    He pulled the old gloves on and unzipped his jacket. I watched as my dad handed him the catalogue and the biker slipped it inside his coat. He jostled it around, positioning it up high, centered, and then zipped it up. I remembered now making sense of why my dad had given him the catalogue. It would keep him a bit warmer. After wishing the biker well, my dad and I left him warming up his bike.

    Two weeks later, the biker came to our home and returned my father’s gloves. He had found the address on the catalogue. Neither my father nor the biker seemed to think that my dad stopping at the side of the road for a stranger and giving him a pair of gloves, and that the stranger making sure that the gloves were returned, were events out of the ordinary for people who rode motorcycles. For me, it was another subtle lesson.

    It was spring of the next year when I was sitting high on my throne, watching the farm fields slip by when I saw two bikes coming towards us. As they rumbled past, my dad and I waved, but the other bikers kept their sunglasses locked straight ahead and did not acknowledge us. I remember thinking that they must have seen us because our waves were too obvious to miss. Why didn’t they wave back? I thought all bikers waved at one another…..

    I tapped my dad on the shoulder and yelled…”How come they didn’t wave back?”

    “Don’t know. Sometimes they don’t.”

    I remember feeling very puzzled. Why wouldn’t someone wave back?

    The next summer, I was finally old enough to learn to ride a motorcycle with a clutch. Many an afternoon were spent on a country lane beside our home, kicking and kicking to start my dad’s old 1955 BSA. When it would finally come to a sputtering start, my concentration would grow to a sharp focus, as I tried to let out the clutch slowly enough, and bring us to a smooth take off. More often than not, I would lurch forward…..and begin to attempt to kickstart the motor again.

    Eventually, I got my own motorcycle license, and began wandering the backroads on my own. I found myself stopping along sideroads if I saw another biker alone, just to check and see if he needed help…….and I continued to wave at other riders.

    But I remained focused as to why some riders never waved back. It left me with almost a feeling of rejection, as if I were reaching to shake someones hand, but they kept their arm hanging by their side.

    I began to canvass my friends about waving. I talked with people at biker events, asking what they thought. Most of the old riders told me they waved to other bikers and often initiated the friendly air handshake as they passed one another.

    I did meet some riders tho, who told me that they did not wave to other riders because they felt that they were different from other bikers. They felt that they were a “breed apart”. One guy told me in rather colorful language, that he did not “wave to no wussies”. He went on to say that his kind of bikers were tough, independent, and they did not require or want the help of anyone, whether they rode a bike or not.

    I suspected that there were some people who bought a bike because they wanted to purchase an image of being tougher, more independent, a not-putting-up-with-anyone’s-crap kind of person, but I didn’t think that this was typical of most riders.

    People buy bikes for different reasons. Some will be quick to tell you what make it is, how much they paid for it, or how fast it will go. Brand loyalty is going to be strong for some people whether they have a Harley, Ford, Sony, or whatever… Some people want to buy an image and try to purchase another person’s perception of them. But it can’t be done.

    Still, there is a group of people who ride bikes who truly are a breed apart. They appreciate both the engineering and the artistry in the machines they ride. Their bikes become part of who they are and how they define themselves to themselves alone.
    They don’t care what other people think. They don’t care if anyone knows how much they paid for their bike or how fast it goes. The bike means something to them that nothing else does. They ride for themselves and not for anyone else. They don’t care whether anyone knows they have a bike. They may not be able to find words to describe what it means to ride, but they still know. They may not be able to describe what it means to feel the smooth acceleration and the strength beneath them. But they understand.

    These are the riders who park their bikes, begin to walk away and then stop. They turn and look back. They see something when they look at their bikes that you might not. Something more complex, something that is almost secret, sensed rather than known. They see their passion. They see a part of themselves.

    These are the riders who understand why they wave to other motorcyclists. They savour the wave. It symbolizes connection between riders, and if they saw you and your bike on the side of the road, they would stop to help and might not ask your name. They understand what you are up against every time you take your bike on the road…..the drivers that don’t see you, the ones that cut you off or tailgate you, the potholes that lie in waiting. The rain. The cold.

    I have been shivering and sweating on a bike for more than 40 years. Most of the riders that pass give me a supportive wave. I love it when I see a younger rider on a “crotch rocket” scream past me and wave. New riders carrying on the traditions.

    I will continue in my attempts to get every biker just a little closer to one another with a simple wave. And if they do not wave back when I extend my hand into the breeze as I pass them, I will smile a little more. Maybe their just mistaken about who is a “breed apart.”