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.
2002 919 40,000 miles
"racing is life...everything else is just waiting"
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.
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.
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!