Tag Archives: Motorcycles

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 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!

  • 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.”