Engine modifications for old Kawi twin - Wrist Twisters
 
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post #1 of 9 Old 11-13-2006, 05:39 PM Thread Starter
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Engine modifications for old Kawi twin

This is for those of you familiar with the old KZ440 twin from Kawasaki. I have a 1983 440 LTD that is my current cafe racer project bike. Does anyone know where I can get some info on engine mods for this thing? Port/polish, overbore, anything? I can take things apart and replace parts, but this kind of thing is beyond me so any pointers would be great.

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post #2 of 9 Old 11-15-2006, 07:13 PM
 
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Bock, I see your from Illinois. I don't know how close you are to St. Louis, but there is a guy around here who loves doing this sort of thing. I've seen him fit much larger sleeves into an XS650 to make it into an 800, and I've seen him do plenty of porting and head work on lots of bikes. The place is called Performance Machine Service, and the # is (636) 942-4884. His motto is " If you're bike's not bitchin and screamin, it ain't got P.M.S." Anyway, it couldn't hurt to give him a ring.

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post #3 of 9 Old 11-16-2006, 05:18 AM Thread Starter
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Excellent! I thought I'd never get a reply to this thread. Thanks Hooligan! I found a place that will do porting, but nobody seems to sell pistons for the 440. I'll give that guy a ring sometime soon.

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post #4 of 9 Old 11-16-2006, 01:58 PM
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IIRC, the 440, 454, 550, and EX500 all share the same block. You can bore/stroke an EX500 as big as 660.

I had an '81 550LTD when I was in high school that had a habit of sucking the choke plates into the carbs, no matter what you did. I ran the crap out of that bike, though. Very dependable, if uninspiring machine.

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post #5 of 9 Old 11-16-2006, 02:16 PM
 
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Originally Posted by Bock919 View Post
Excellent! I thought I'd never get a reply to this thread. Thanks Hooligan! I found a place that will do porting, but nobody seems to sell pistons for the 440. I'll give that guy a ring sometime soon.
This guy will dig into his books and find pistons that will work from another machine. I've seen him trim skirts on his lathe so that the bottom won't hit the crankshaft. I had a 1971 Suzuki TC90 and no one made a piston for it anymore, so he found one that was for some kind of suzuki three wheeler and made it work. He's been doing this sort of thing for a long time, so he could probably help. I know for a fact that he has the equipment to do sleeves. Anyhow, good luck!

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post #6 of 9 Old 12-01-2006, 08:40 AM Thread Starter
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Just an update: this is a current photo. Obviously it's a work in progress (note the lack of carbs).

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post #7 of 9 Old 12-01-2006, 10:41 AM
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Quote:
Originally Posted by Bock919 View Post
Just an update: this is a current photo. Obviously it's a work in progress (note the lack of carbs).
Man that thing looks like a lot of fun!! (well when it's running)

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post #8 of 9 Old 12-02-2006, 03:44 PM
 
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That thing's gonna be pretty cool! Did you have that seat custom made?

Someday I want to find an old two cycle enduro (DT400 probably) and do the same thing.

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post #9 of 9 Old 12-02-2006, 07:23 PM Thread Starter
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I actually found the seat on ebay. It was made from a Honda 350 seat pan. The clipons were fabbed by my bro, though.

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