1985 Kawasaki 454 to Bobber

[Hortons Heroes]

Wanted to start a thread for my next build.

I bought a 1985 kawasaki that was a score on Kijiji about a month ago. Not running (ran about 5 years ago but they couldn't get it going again) but I was looking for another project to get going this fall.

Just got it idling tonight (after a few weeks of tinkering) and am thrilled that it works. This was my first not starting bike that I have bought.
Working with Ben we found it had
-a dead plug 
-some local wildlife living and then dying in the carb
-float needle would not seat correctly and kept dumping gas.

With some wisdom stolen off this forum I got the carb all apart and solved the float needle issue. (Thanks Fast1)

Next is to get a coat of paint on the tank, reconnect some wiring in the back, order some fork seals and then possibly replace the turn signal relay.

All the other electrical seems to work which is awesome. New oil, filter, brake fluid flush, coolant flush and it should be a bit more trustworthy on the road. Going to insure tomorrow and hopefully get a short ride in.

Plan is to leave it stock over the summer and get a plan/parts together to start chopping for the Tune Up Weekend at Ness Lake in September.

This is not my exact bike but gives an idea of the stock look. Has some wicked long forks for a stock bike.


This is a start for what I am thinking of working towards. I love some of the ideas but am only just getting my head around what a bobber is.


EDIT-I just realized that this bike is only from 1985 and with most people definition of vintage being 30 years old I guess it will have to wait two more years before it's really and truly vintage.

[thejij]

Hey.. that looks like Pauls winter find !!! Now we will have two 454s running around town !

[Hortons Heroes]

Was going to go black but was convinced otherwise. Two black stripes coming soon.



Here is a video of the first running. SO StOKED!!!
https://www.facebook.com/photo.php?v=10152799430475567&l=8348956051906032308

[Hortons Heroes]

Went for a 2 1/2 hour ride out past Giscome with a passenger and stock bars and had a hoot! Love this bike but the bar position had my arms bent a lot and my wrists tweaked more than I wanted. I got a set of renthal bars at the honda yard sale for cheap and mounted them on tonight. LOVE THE NEW POSITION!! Can't see much in the mirrors any more as the old bars had them looking over the shoulder and these ones look right at my biceps. Either way love the new bars and a short ride was a blast.

Side view of stock and new bars



My view of stock and new bars



Flushed the brakes, coolant and did an oil change and things are running quite nicely now.

While on my Giscome trip my rad fan turned on for the first time....then it never turned off. I read some forums and lots of folks were just attaching a switch as the fan runs even with the key out. I put the switch infront of the tank and just behind the forks, found out today I put it about 3/4 of an inch to far forward and if I really steer hard it turns the fan off. Dang it.


Put in a new relay and got the signals working as well. Pretty sure most of the gremlins are out, now for something major to fail.

I am noticing that this bike seems to be a bit more temperature temperamental.  Even when I warm it up idiling when it's colder out it doesn't seem run as smoothly on the road. Does the liquid cooling make these bikes way more finicky for cold weather starting and riding? All my other bikes have just been air cooled.

[Trollden]

Your tank turned out great....I am looking forward to additional changes to your bike as I have a similar bike (84 Virago) that is not being used that I would like to make into a bobber - just don't have the guts to pull the trigger on the project yet!  Or the skill for that matter     Anyhow, good work and keep the pictures coming....

Todd

[Hortons Heroes]

There won't be to many updates until the Tune Up weekend in Sept. I got most of the bugs out and now my friend is renting it for the summer. I saw him on it twice today, the two tone yellow and red looks a little goofy. When I get the bike back in the fall I will start really chopping.

[fast1]

   The engine in your 454 (and Paul's) is based on the 900 Ninja of the same era. They simply removed the 2 center cylinders and narrowed it up. Part numbers for many things like pistons and valves, crank seals and some clutch parts are the same. It is also the same engine used in the entry level EX 500 Ninja, which they still make so parts availability should not be an issue for some time to come. Took my second class 6 test on one. If your license is expired for more than 3 years you have to re-test. Little screamer , guaranteed to put a smile on your face. Little bit quicker than the CM'S huh Dave? Much like their big brother these bikes need a proper warm up. Liquid cooling is more to keep the temp. constant than cold. Engines need to reach a certain temp. before they run smoothly. Liquid cooling is on the top end only. The crank relies on oil and air flow alone. That is why your crank case has cooling fins. The cold water around your cylinder prevents the steel sleeve from heating and expanding at the same rate as your rapidly moving piston. Zap the throttle and ride away you will cold seize the piston or at the very least scuff it. You should not ride away until the cylinders are warm to the touch, not hot just warm enough to notice then take it easy for the first 5 k. CHEERS.

[Hortons Heroes]

Well turns out I hate paying the extra in insurance for the 454 so I am going to do my cm 400 bobber build. Thread to start soon.

[Sr.X]

ICBC knows that extra 54 cc's make you a HUGE insurance risk. We have to trust them, they only have our best interests at heart. I'm always glad when they can give themselves a big bonus when they make a huge profit. Isn't that what government owned companies are supposed to do.

  Later, Bob