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Author Topic: 75' KZ400 Tracker/Enduro: Near Completion  (Read 4687 times)

Offline AimlessMoto

  • Posts: 156
  • Blood, sweat and beers.
75' KZ400 Tracker/Enduro: Near Completion
« on: Aug 17, 2016, 22:15:15 »
A couple months ago I picked up 2 75' KZ400's... $300!

The blue on has a disc brake and electric start, the red one is the S model with JUST a kick start... which I promptly broke after getting the engine to fire on 1 cylinder.

Blue one, 8200 miles, Red one, 5500 miles...

So, I decided I'd tear into the red one because I heard it "run"... and convert it to an electric start but keep the drum brakes... because NO ONE keeps them, and they're more reliable than a 70's disc any day of the week.


Here it is as of NOV 2016.



Here it is as of MAY 2017.




Here it is when I got it home in Aug of 2016:
« Last Edit: Jun 01, 2017, 01:23:02 by AimlessMoto »

Offline AimlessMoto

  • Posts: 156
  • Blood, sweat and beers.
Re: 75' KZ400
« Reply #1 on: Aug 17, 2016, 22:39:01 »
The first thing I did was pop the carbs off and give them a rebuild... all I will say is THANK GOD I got 2 bikes in this deal, one carb's idle jet was goosed... had to rob the left carb body from the other bike to even move forward.

Boiled the bodies in lemon juice for about 25 minutes, gave everything a good scrub, and polished the caps, bowls, and all the brass bits.

« Last Edit: May 10, 2017, 12:36:51 by DannyMotor »

Offline AimlessMoto

  • Posts: 156
  • Blood, sweat and beers.
Re: 75' KZ400
« Reply #2 on: Aug 17, 2016, 22:43:01 »
After the frame was stripped I started hacking off all the tabs.

I also hacked the right-side exhaust/passenger peg mount and trimmed it down. No passengers on this ride!

Then I widened the left-side swing-arm mount for the shock... had to space the wider shocks away from the chain a bit.




« Last Edit: May 10, 2017, 12:39:30 by DannyMotor »

Offline AimlessMoto

  • Posts: 156
  • Blood, sweat and beers.
Re: 75' KZ400
« Reply #3 on: Aug 17, 2016, 22:46:54 »
I picked up an ammo box from a local army surplus. Took to hacking it up, and making a couple brackets for it to fit as a new battery box. Didn't come out too bad as a first attempt. Also worked out re-locating the rear fender. I really like this line.

As you can see, trying to keep as many stock parts as possible on this bike.



« Last Edit: May 10, 2017, 12:41:11 by DannyMotor »

Offline AimlessMoto

  • Posts: 156
  • Blood, sweat and beers.
Re: 75' KZ400
« Reply #4 on: Aug 17, 2016, 22:50:19 »
Took a weekend and painted everything up! You can see inside the battery box how I hacked the mount for the regulator off the original box and welded it to the bottom. Also welded in a place to mount the battery to and the starter solenoid.

Everything painted up nice! The battery box is just in flat primer to prevent rust. It will still need some fixes. You can also see the new shocks... $59 on ebay... can't complain.

« Last Edit: May 10, 2017, 12:42:23 by DannyMotor »

Offline AimlessMoto

  • Posts: 156
  • Blood, sweat and beers.
Re: 75' KZ400
« Reply #5 on: Aug 17, 2016, 22:55:03 »
Got the engine back in and started POLISHING! Timing covers, valve adjustment covers, and the letters on the cases are the ONLY parts being polished... thank God. Nearly killed myself doing all the polishing on the GS750 a few years back... will NOT do that again.

This time around... WRINKLE finish everywhere!

Also, new tires came in. Kenda K270's... 3.50 x 18. Should do the trick.

« Last Edit: May 10, 2017, 12:44:06 by DannyMotor »

Offline mitchn06

  • Posts: 26
Re: 75' KZ400
« Reply #6 on: Aug 18, 2016, 00:53:04 »
Good work!


Sent from my iPhone using Tapatalk

Offline hillsy

  • Posts: 4104
Re: 75' KZ400
« Reply #7 on: Aug 18, 2016, 00:58:53 »
also got in some cheap shocks, need to space them away from the chain... so I added about 3/16 of material into the lower mount on the swing arm.





You need a bolt with a longer shoulder so it goes through the eye of the shock. Using that bolt with the thread will eat away at the shock rubber.

Offline hillsy

  • Posts: 4104
Re: 75' KZ400
« Reply #8 on: Aug 18, 2016, 00:59:37 »
BTW - nice work on the engine cover wrinkle paint  8)

Offline AimlessMoto

  • Posts: 156
  • Blood, sweat and beers.
Re: 75' KZ400
« Reply #9 on: Aug 18, 2016, 14:22:11 »
BTW - nice work on the engine cover wrinkle paint  8)

Thanks! It's a pain in the butt... haha.

As for the lower shock bolt, the shocks have a steel bushing that goes between the rubber bushing and the bolt... so no worries about shredded rubber! I may need to get a LONGER bolt, however, as only 3 or 4 threads will bite now that I've extended it.