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KZ400EE Chop rebuild

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Ace Rimmer
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PostPosted: 13:59 - 25 Apr 2020    Post subject: KZ400EE Chop rebuild Reply with quote

Here We go then,

Some pics of my project bike. A 3/4 way finished project all I need to do is finish it off!

Has spent a few years sitting about so I was pretty chuffed when it turned over by hand! After checking the electrical system most things work, so have just received new coils when I noticed the crack on the block by the engine mount so all is stopped until I know its a repairable thing =(
I wont be starting from scratch as this one is a bit special for me and worth the extra effort. The work gone in so far justifies it for me!
The plan was to just get the engine running well then work on the rest of the bike to get it road ready in maybe 8 weeks time. But as I'm taking out the engine it'll be nice to have the chance to inspect the frame and have more through approach to the whole project.

Other than that all I need is :
Rear brake assembly
Forks
Lights
Seat
Clutch/throttle cables + gear
Strip + re-jet carbs for trumpets
Mot
+more I'm sure!

Will be updating with more pics as I go.

Hope you like!
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Riejufixing
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PostPosted: 14:16 - 25 Apr 2020    Post subject: Reply with quote

What the hell's happened to the back of the frame?
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Ace Rimmer
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PostPosted: 14:23 - 25 Apr 2020    Post subject: Reply with quote

The previous owners work, Plan is its a single seater hence the removal of the rear foot peg mounts as well. The bike sure has some style as a one seater for sure really does depend on how i decide to roll the tube for the back. to lip? or keep flat?
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Nobby the Bastard
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PostPosted: 15:57 - 25 Apr 2020    Post subject: Reply with quote

What to do with the pipes where the rest of the frame used to be?

Scrap the whole fucking frame. It has no structual integrity left.

Alternately, make sure someone is filming it the first time you try and take a corner on it. We all enjoy a laugh at stupendous crashes.
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stinkwheel
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PostPosted: 17:48 - 25 Apr 2020    Post subject: Reply with quote

Wow, someone needs their angle-grinder licence revoking!.

That's going to take a bit of bracing up again. Zed frames are bendy enough to start with.

They had a bit of a kick-up at the end of the tailpiece as standard didn't they?

Is that half a slug I see sticking out of the right hand frame rail. They were just going to slug and butt weld it? Gonna want some gussetting in there somewhere. Just not sure where, not been left a whole lot of meat to work with.
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I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.
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Riejufixing
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PostPosted: 20:45 - 25 Apr 2020    Post subject: Reply with quote

Ace Rimmer wrote:
The previous owners work, Plan is its a single seater hence the removal of the rear foot peg mounts as well. The bike sure has some style as a one seater for sure really does depend on how i decide to roll the tube for the back. to lip? or keep flat?

You'll get there. I like your centre stand, by the way. Unsure what "how i decide to roll the tube for the back. to lip? or keep flat?" means, sorry.
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virus
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PostPosted: 21:25 - 25 Apr 2020    Post subject: Reply with quote

What stink said.

Whatever happens behind that rear shock mount, make sure theres a cross brace joining the 2 ends up otherwise it'l handle like a hippo thats eaten a bag of ketamine.
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own: 81 xs1100g...
owned: 85 rat CG (sold), 91 GS500e (stolen), 84 gsx400f (scrapped), 81 z250 (siezed, siezed, scrapped), 83 cb250rs (sold), 84 gpz750r ratfighter (killed) 84gpz400 (sold), '80 cb650 ratfighter (wrote off) 95gsx6/12f ratfighter (killed) 91 xj900 (sold)
stinkwheel Well I just had my hands up a pigs fanny. Which makes your concerns pale into insignificance.
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Ace Rimmer
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PostPosted: 12:49 - 26 Apr 2020    Post subject: Reply with quote

OK So gona finish this engine removal today, ended up with a couple too many drinks in me on a sat afternoon in the yard to finish yesterday, now with a blistering hangover all to do now is exhaust stud removal, then slip it on out. You can imegine what I'm looking at....

stinkwheel - Yep your right it originally a little kickup there, but not sure about the styling, thats a bit far away now but if well considered, could hide some bracing required on the rear SF, maybe even some mounting pints for a couple of small leather panniers. Is good to consider now whilst the engine is out.
Yes thats a slug, cant remember the term for the procedure I'll be using but for sure it'll not be structural. I've a few ideas on the fabrication of this bracket but Im open to ideas on this!


Riejufixing - Nice one thanks,
Also we are constantly developing our centerstands, this is one of our 100% biodegradable environmentally friendly free range barn fed models. [/quote]
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stinkwheel
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PostPosted: 13:43 - 26 Apr 2020    Post subject: Reply with quote

Ace Rimmer wrote:

stinkwheel - Yep your right it originally a little kickup there, but not sure about the styling, thats a bit far away now but if well considered, could hide some bracing required on the rear SF, maybe even some mounting pints for a couple of small leather panniers. Is good to consider now whilst the engine is out.
Yes thats a slug, cant remember the term for the procedure I'll be using but for sure it'll not be structural. I've a few ideas on the fabrication of this bracket but Im open to ideas on this!


I can't stress enough how badly that's been butchered. It's not structurally sound, The two sides of the rear of the frame will flex independantly and you risk the shock mounts coming adrift. Frame will probably snap after a while if it's not properly sorted out.

They have cut the gussets that support the rear shock mounts off with the back of the subframe. It'll need a cross-braced loop bending up, slugging and welding in and new gusset plates and shock mounts.

Here's what you are supposed to have there:

https://www.bikechatforums.com/download.php?id=103416

The strength on those gusset plates is all in the tiranguation. Yours are no longer triangular.
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.
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Bhud
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PostPosted: 14:20 - 26 Apr 2020    Post subject: Reply with quote

I suppose nothing is truly beyond repair, but there is a point where it ends up being more costly or time-consuming than it's worth.

If I had that project on my hands, I would probably try and look into getting the frame repaired or braced first, and then looking for a competent welder with a good reputation to fix the broken engine mount, or trying to source a replacement crankcase.

Once I had all the costs available to me, I would try and compare them with the price of replacing the frame and/or engine. I don't want to break the rules by posting in the wrong subforum so I've sent you a PM.
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WD Forte
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PostPosted: 15:11 - 26 Apr 2020    Post subject: Reply with quote

Apart from the need of a good bracing between the points above the shock mounts as previously mentioned, I dont see it as a lost cause at all
Tubework after the cut only supported the seat.

Compared to the form over function retards who ruin the structural integrity of old CXs by converting skinny CX swinging arms to mono shocks, its a pretty harmless mod
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stinkwheel
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PostPosted: 15:29 - 26 Apr 2020    Post subject: Reply with quote

WD Forte wrote:

Tubework after the cut only supported the seat.


And the shocks. It's all structural up to the end of that pressed steel "arch".
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.
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Ace Rimmer
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Joined: 25 Apr 2020
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PostPosted: 17:35 - 26 Apr 2020    Post subject: Reply with quote

Well here it is:

2/4 outlet exhaust broken
Bits and pieces left of the casing
rear mount rusted through
Hole in frame under rear brake pedal
Broken carburettor
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Nobby the Bastard
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PostPosted: 17:48 - 26 Apr 2020    Post subject: Reply with quote

This is going to be thin as fuck and a nightmare to fix.

https://cdn.bcf.44bytes.net/files/20200426_160954_copy.jpg
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trevor saxe-coburg-gotha:"Remember this simple rule - scooters are for men who like to feel the breeze on their huge, flapping cunt lips."
Sprint ST 1050
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Riejufixing
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PostPosted: 18:55 - 26 Apr 2020    Post subject: Reply with quote

Ace Rimmer wrote:
Well here it is: ( 8< )

Can you weld?
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stinkwheel
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PostPosted: 21:20 - 26 Apr 2020    Post subject: Reply with quote

It's not a motorcycle. It's a mud anchor. So many structural problems and you haven't even looked inside the motor yet.

I'd cut my losses. Look for a spares or repair one and use this as a parts donor. Hopefully some of the engine internals are still useable.
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.
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P.
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PostPosted: 08:56 - 27 Apr 2020    Post subject: Reply with quote

Oh look, dead weight Laughing

Scrap time. Fun time.
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Nobby the Bastard
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PostPosted: 11:09 - 27 Apr 2020    Post subject: Reply with quote

Paddy. wrote:
Oh look, dead weight Laughing

Scrap time. Fun time.


Aren't you going to offer to buy it?
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trevor saxe-coburg-gotha:"Remember this simple rule - scooters are for men who like to feel the breeze on their huge, flapping cunt lips."
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WD Forte
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PostPosted: 15:36 - 27 Apr 2020    Post subject: Reply with quote

You people....
Yes, there, I said it
You people
whining on about a tiny speck of rust
All you see is problems

I see opportunities

https://imgur.com/2Mp4xpD.jpg
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MarJay
But it's British!



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PostPosted: 15:47 - 27 Apr 2020    Post subject: Reply with quote

https://media.tenor.com/images/a53dc07bf0a6f8822f16c0760299f915/tenor.gif
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P.
Red Rocket



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PostPosted: 16:15 - 27 Apr 2020    Post subject: Reply with quote

Nobby the Bastard wrote:
Paddy. wrote:
Oh look, dead weight Laughing

Scrap time. Fun time.


Aren't you going to offer to buy it?


I buy bikes.
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MarJay
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PostPosted: 16:24 - 27 Apr 2020    Post subject: Reply with quote

Paddy. wrote:
I buy bikes.


https://media.tenor.com/images/1b7e631916a76c1e418ec8c7c83f9e07/tenor.gif

https://media1.tenor.com/images/b3deb97b2daa22f7366f4f1217ebf309/tenor.gif?itemid=10493131

https://media1.tenor.com/images/dc1421d61e066a5319b4971fee179bf2/tenor.gif?itemid=3569646
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British beauty: Triumph Street Triple R; Loony stroker: KR1S; Track fun: GSXR750 L1; Commuter Missile: GSX-S1000F
Remember kids, bikes aren't like lego. You can't easily take a part from one bike and then fit it to another.
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Bhud
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PostPosted: 11:33 - 02 May 2020    Post subject: Reply with quote

You can't just leave it hanging! What did you decide to do? Just curious.
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Riejufixing
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PostPosted: 12:44 - 02 May 2020    Post subject: Reply with quote

It seems to me to be one of those things that's possible given the expertise or the money. Bit of welding/brazing, head, mount, more bits 'n' bobs of course, but given the desire to do the job is still a possible.
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lilredmachine
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PostPosted: 22:57 - 03 May 2020    Post subject: Reply with quote

Riejufixing wrote:
It seems to me to be one of those things that's possible given the expertise or the money. Bit of welding/brazing, head, mount, more bits 'n' bobs of course, but given the desire to do the job is still a possible.


Yeah, but why? It was worth fuck all before some asswipe fucked the frame, and then it turned out to be full of tin worm. Which incidentally, makes the already compromised structural integrity of the frame even more desperate.

At this point, find a frame, find a motor, just buy a new bike to cut up maybe?

losses need to be cut more than the wrist veins of the original 'modder' Laughing

Also, I direct you to the OP:

Quote:
Some pics of my project bike. A 3/4 way finished project all I need to do is finish it off!


I don't think we're dealing with the type of whizzkid that has the skills to deal with the level of fuckage seen here. Anyone with half an ounce of mechanical nouse and sympathy could have sensed how trash this thing was from at least 25 foot away. Very Happy
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Last edited by lilredmachine on 23:04 - 03 May 2020; edited 1 time in total
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