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Old 10-27-2009, 05:15 PM   #1
lamoson OP
something catchier
 
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Joined: Mar 2008
Location: Wiscompton
Oddometer: 680
1981 KZ440 LTD cafe/street tracker project

ok so this will probably be a long ongoing post, as i don't always have tons of time to work on it, and money is REALLY tight. but i did get the bike for free, so that helps a ton.

the bike is 81' 440 ltd. the plan is to make it into something a little more appealing. sorry all you ltd lovers. so lets go straight to the pics

first the inspiration




this is where the bike was living for the past five years








something dead was in there


all washed up


the start of the teardown






i got her started!!!!! wahoo! but she didn't run all that great. could only get it to idle. any time i gave it gas, it would die.

i know i need to clean out the carbs and that will help a ton. i just wanted to make sure there wasn't something that i need to do first or something that may be wrong. i am new to the whole twin thing. to help i decided to also include a video, i hope it is loud enough. let me know if there is anything that i should do before i continue the teardown.


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2005 KTM 250sx......love it!!!!!!

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Old 10-27-2009, 05:41 PM   #2
CLynn85
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Location: South of Northern Virginia
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Having just picked up an 82 KZ440, I'm definitely tuning into this one. I have the same inspirational photos, but I'm more worried about learning to ride better than customizing at this point.
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Old 10-27-2009, 06:30 PM   #3
anonny
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Joined: Mar 2007
Location: Beautiful Revelstoke BC
Oddometer: 5,459
Once you take the mouse nest out of the air cleaner/ carbs it should run better
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Old 10-28-2009, 02:03 PM   #4
comes naturally
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Location: SE PA
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I just picked up a 79 kz400...
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Old 10-28-2009, 03:08 PM   #5
lamoson OP
something catchier
 
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Joined: Mar 2008
Location: Wiscompton
Oddometer: 680
changed the oil today and surprisingly it didn't look too bad. no more luck on getting her running better though. i am trying to bring that battery back to life right now, added water and putting a charge on it, but i am doubting it will hold a thing. it is a bummer there is no kicker on this thing. i am debating weather i leave it together and try and get those carbs dialed before the teardown, or if i should just strip the thing to bits and work up from there. what do you think?
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2005 KTM 250sx......love it!!!!!!

81' Cafe project http://www.advrider.com/forums/showthread.php?t=519776

80' XL80 http://www.advrider.com/forums/showt...highlight=XL80
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Old 10-28-2009, 03:16 PM   #6
kz1
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Location: Ohio North Coast
Oddometer: 780
Additional information

For additional information, the KZ owner's website:

www.kzrider.com
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Old 10-28-2009, 04:39 PM   #7
lamoson OP
something catchier
 
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Joined: Mar 2008
Location: Wiscompton
Oddometer: 680
Quote:
Originally Posted by kz1
For additional information, the KZ owner's website:

www.kzrider.com

thanks hadn't found that one yet http://www.armbell.com/forum/ this is a good one too.
__________________
2005 KTM 250sx......love it!!!!!!

81' Cafe project http://www.advrider.com/forums/showthread.php?t=519776

80' XL80 http://www.advrider.com/forums/showt...highlight=XL80
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Old 10-28-2009, 08:22 PM   #8
lamoson OP
something catchier
 
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i have been doing some reading on carbs. looks like if i am gonna run these without the stock airbox, and different exhaust, they aren't gonna run so well. should i be looking for different carbs? if so what should i look for and should i go 2-1 with it? wouldn't be too hard to fab up the connections.
__________________
2005 KTM 250sx......love it!!!!!!

81' Cafe project http://www.advrider.com/forums/showthread.php?t=519776

80' XL80 http://www.advrider.com/forums/showt...highlight=XL80
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Old 10-29-2009, 10:47 PM   #9
lamoson OP
something catchier
 
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progress! so i fiddled a bit today. i hooked up a jump pack and got it going when i would take off the pack to put the airbox on it would die. so i made a make shift filter with two paper towels. i couldn't believe it, revved right up! i was surprised. here is a vid. so how does is sound?

__________________
2005 KTM 250sx......love it!!!!!!

81' Cafe project http://www.advrider.com/forums/showthread.php?t=519776

80' XL80 http://www.advrider.com/forums/showt...highlight=XL80
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Old 10-30-2009, 04:05 PM   #10
comes naturally
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What kind of video camera do you have?

comes naturally screwed with this post 10-31-2009 at 08:14 AM
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Old 10-30-2009, 09:48 PM   #11
tenderfoot
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Joined: Feb 2006
Location: Gauteng, RSA
Oddometer: 1,446
Quote:
Originally Posted by lamoson
progress! so i fiddled a bit today. i hooked up a jump pack and got it going when i would take off the pack to put the airbox on it would die. so i made a make shift filter with two paper towels. i couldn't believe it, revved right up! i was surprised. here is a vid. so how does is sound?
It sounds just as I remember the one my wife had BC. (Before Children)

Believe me, you've got a seriously nice little bike there.
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Old 10-31-2009, 05:48 PM   #12
lamoson OP
something catchier
 
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Joined: Mar 2008
Location: Wiscompton
Oddometer: 680
Quote:
Originally Posted by comes naturally
What kind of video camera do you have?
http://vholdr.com/

well worth the money. i love it. and the new model shoots in 1080p.


as for the bike, planning on trying to ride it around the block tomorrow, just to see if there is anything i need to address before the tear down. i hope the tires last, got some pretty sweet dry rot going on em. i will just keep it slow. maybe i will take some video.
__________________
2005 KTM 250sx......love it!!!!!!

81' Cafe project http://www.advrider.com/forums/showthread.php?t=519776

80' XL80 http://www.advrider.com/forums/showt...highlight=XL80
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Old 11-01-2009, 09:15 PM   #13
lamoson OP
something catchier
 
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Joined: Mar 2008
Location: Wiscompton
Oddometer: 680
took it around the block to see how she rides. not bad. the carbs could use some tuning, but everything else seems ok. here is the vid. sorry about the wind



now for the real work!!! time to TEAR DOWN
__________________
2005 KTM 250sx......love it!!!!!!

81' Cafe project http://www.advrider.com/forums/showthread.php?t=519776

80' XL80 http://www.advrider.com/forums/showt...highlight=XL80
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Old 11-02-2009, 02:58 PM   #14
zap2504
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Joined: Feb 2006
Location: Middletown, PA
Oddometer: 551
I also have an '81 440 LTD that I've been working on (seems like forever). But mine did not run llike yours. So far I've replaced the rubber intake manifolds (common problem in most bikes this old), removed the front master cylinder (mine was filled with rust and spooge - it's generally regarded as a piece of junk anyway) and am in the process of converting the "buckhorn" bars to more of a standard/superbike bar setup (need to install Yamaha straight-mount MC and different front turn signals). As you have found, the 440 LTD does not like to run without the stock air filter (but you can get away with MAC 2-1 exhaust for appearance sake) nor a fully charged battery (electronic ignition). Since your bike seems to be running quite well now, check the charging system, flush the brake lines, disconnect/clean/lube (with dielectric grease)/reconnect all the wires and keep it running while you decide about a custom appearance. The KZ Twins site has answers to about any question you can come up with.
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Old 11-02-2009, 03:38 PM   #15
lamoson OP
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Location: Wiscompton
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yea my master cylinder is shot too. so nasty. i started to really tear it down last night. i am going to tear down to everything but the motor. then i will chop and weld, do lights, bars, new switches, seat, fork boots.

i will re-assemble when that is taken care of, maybe address the carb issue then. still not sure if i can make those work with pod filters or not, haven't found a clear answer. if not, i will need to decide what to do with the carbs, still go two or make it a 2 to 1. anybody recommend any carbs. cheap is preferable.
__________________
2005 KTM 250sx......love it!!!!!!

81' Cafe project http://www.advrider.com/forums/showthread.php?t=519776

80' XL80 http://www.advrider.com/forums/showt...highlight=XL80
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