75' KZ400 Tracker/Enduro: Near Completion

Re: 75' KZ400: 2017 Updates!

Annndddd..... done!
 

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Re: 75' KZ400: 2017 Updates!

Just standard 7/8 super-bike bars. Parts-Unlimited specials through Bike Bandit.
 
Re: 75' KZ400: 2017 Updates!

So, took it for a maiden in its new form, and i absolutely love it. One problem... it left me stranded 45 mins into the ride. I got a jump from a local, and was able to get home by keeping the revvs up above 6k the whole way.

Got it into the garage and did a quick recon. Battery at 10v, r/r showing good resistance on all 3 poles, then started it and checked each leg of the stator. 1 was at 50a, one at 55a, and one at 0. Checked with a beeper and its not grounded... just open.

So I checked the donor bikes stator (luckilly it was off and I could bench test), and all 3 legs are good... no ground outs, and all show 0.9-1.0 ohms resistance between all legs + and -.

Looks like Im moving forward with a stator swap.
 
Re: 75' KZ400: 2017 Updates!

Found out the problem wasnt really a problem... it was a parts issue. I left the stator for the kick-start engine in when i installed the starter from the other bike. Turns out they are different part numbers... and the kick-start stator isn't 3 phase.

Swapped the stator in about 20 minutes. Fired it up with 11.6v on the battery and it quickly jumped to 13.7v with a steady throttle at 3k rpm. The old stator would barely keep above 12v when running.

Test ride tomorrow!
 
Re: 75' KZ400: 2017 Updates!

Woohoo! Got the new stator in and its charging perfectly!

After the bike warmed up (this has been a constant problem) the idle went wonky. I tore into the carbs again... balanced them, did everything in the book... until I found the answer.

I installed the butterflies backwards and they werent sealing. Didnt even notice they were tapered on the edges. Flipped them around... re-timed, did the valves, checked the points, gapped the plugs, balanced the carbs again... and we have a runner! Let it idle for a good 10 minutes... kept blipping every minute or so.. rock-steady idle! Even with my pods and custom pipes, shes a runner! Now to put some miles down!

All the extra tinkering led me to build an actual bike bench... shop is coming together.
 

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Re: 75' KZ400: 2017 Updates!

wish the photos werent upside down... thats a sharp lookin bike man
 
Re: 75' KZ400: 2017 Updates!

Hahaha, didnt even notice that... let me fix...
 

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Re: 75' KZ400: 2017 Updates!

I shot a few vids... this one has it running and riding half way through with the two under-pipes. Im editing together the next in the series with the high pipe. Should be out in the next week or so.

Tu5zMkrURfM


https://youtu.be/Tu5zMkrURfM
 
I jumped over the last hurdle today.

I had been fighting a "cruising" hesitation/gurgle around 3-4k rpm.

The hesitation was caused by using these needles from a rebuild kit turns out they were 2mm longer than stock. Put the stock ones in and its 99% better. I think i still may need to down-jet from the 72 mains to 68s. We'll see.
 
Agreed. I watched parts 1-5 a couple days back. Nice work. Waiting patiently (kinda) for next episode...
 
Headlight has become a problem. Cheap $20 ebay nonsense. The bulb got so hot it warped the plastic lens... then the vibrations killed both hi and lo beams... bought an LED bulb... and broke the housing to the headlamp trying to install...

Such crap. On the search for a better housing with a glass lens.
 
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